DCF 280-500 Workshop Manual PDF

A Foreword
B Safety
C Preventive maintenance
0 Complete machine
1 Engine
Workshop manual
2 Transmission
3 Driveline/axle
4 Brakes
5 Steering
6 Suspension
7 Load handling
8 Control system
9 Frame, body, cab and accessories
10 Common hydraulics
11 Common electrics
12 Common pneumatics
D Error codes
E Schematics
F Technical data
G Terminology and Index

A Foreword 1
A Foreword
Table of Contents A Foreword

mm mm mm mm mm mm
Foreword......................................................................................................... 3
About the Workshop Manual ...................................................................... 3
General ............................................................................................................. 3
Conditions ......................................................................................................... 3
Storage .............................................................................................................. 3
About the machine version ................................................................................ 3
Copyright ........................................................................................................... 3
Reading instructions ................................................................................... 4
Warning information .......................................................................................... 4
Important information ........................................................................................ 4
Read the Operator’s Manual ............................................................................. 4
Read the Maintenance Manual ......................................................................... 4
Workshop manual contents ............................................................................... 5
Function group structure ................................................................................... 6
References between different information types ............................................... 7
Product alternatives and optional equipment .................................................... 8
Machine card ..................................................................................................... 8
Function descriptions ........................................................................................ 9
About the documentation ......................................................................... 12
Documentation sections .................................................................................. 12
Ordering of documentation .............................................................................. 12
Feedback .................................................................................................. 13
Form for copying ............................................................................................. 13
Workshop manual DCF 280-500 VDCF02.02GB

2 A Foreword
VDCF02.02GB Workshop manual DCF 280-500

A Foreword – Foreword 3
Foreword
mm mm mm mm mm mm
About the Workshop Manual

General
page
–
Thank you for choosing Kalmar Industries as your machine supplier.

We hope that we'll meet your expectations.
Conditions
page
–
The instructions are based on the use of generally available standard

tools. All lifting devices, such as slings, straps and ratchet blocks, must
meet governing national standards and regulations for lifting devices.
Kalmar Industries will not accept any responsibility for modifications
performed without permission from Kalmar Industries or if other lifting
devices, tools or work methods are used other than those described in
this manual.
Storage
page
–
NOTE
The workshop manual should be accessible to service personnel.
About the machine version

page
–
The information in this publication corresponds to the machine's de-

sign and appearance at the time of delivery from Kalmar Industries.
Due to customizations, there may be variations and/or deviations.
Kalmar Industries reserves the right to modify specifications and
equipment without prior notice. All information and data in this manual
are valid at the time of publication.
Copyright
page
–
Kalmar Industries AB
Duplication of the content in this manual, in whole or in part, is strictly
prohibited without written permission from Kalmar Industries AB.
Duplication by any means such as copying, printing, etc., is prohibited.

4 A Foreword – Reading instructions
Reading instructions
Warning information
page
–
Warnings inform on potential dangers which can, if the warnings are

not heeded, result in personal injury or product damage.
DANGER
Situation that may result in serious personal injury,
possible death, if the instruction is not followed.
WARNING
Situation that may result in serious personal injury if
the instruction is not followed.
CAUTION
Situation that may result in damage to the product if
the instruction is not followed.
Important information
page
–
Important information marked with NOTE facilitates the work process,

operation/handling or increases understanding of the information.
NOTE
Information that is important without being safety related.
Read the Operator’s Manual

page
–
The symbol to the left is sometimes found on the machine. It refers to

important information in the Operator’s Manual.
000262
Read the Operator’s Manual
Read the Maintenance Manual

page
–
The symbol to the left is sometimes found on the machine. It refers to

important information in the Maintenance Manual.
001128
Read the Maintenance Manual

A Foreword – Reading instructions 5
Workshop manual contents

page
–
The Workshop Manual contains information to facilitate maintenance

(part replacement) and is a supplement to the Maintenance Manual.
The supplier documentation for engine, transmission and drive axle
also supplements the Workshop Manual. If possible, the Workshop
Manual provides reference to supplier documentation instead of print-
ing the same information twice. Methods for preventive maintenance
and certain checks are found in the Maintenance Manual; no referenc-
es are given. Use the function groups to locate the information in the
Maintenance Manual.
The workshop manual is divided into the following sections.
A Foreword General information about the workshop manual's purpose, con-

tents and reading instructions as well as survey for feedback of
views and any inaccuracies.
B Safety Keep in mind for your safety.
C Preventive maintenance Reference to maintenance manual: Preventive maintenance.
0 Complete machine
1 Engine
Technical description, comprehensive function descriptions and a
2 Transmission
description of the function of components included in the machine,
3 Driveline/axle divided into function groups.
4 Brakes The components used for each function are described under each
subfunction. Consequently, common components are described in
5 Steering several places, but in general under the first function to use the
6 Suspension component.
Together with the general description is a detailed description of
7 Load handling
what is unique about the specific subfunction. The next subfunc-
8 Control system tion to use the same component only has a description what is
unique for the new function.
Work instructions for corrective maintenance (replacement of
components).
11 Common electrics
12 Common pneumatics
D Error codes Error code information and instructions for reading error code in-
formation.
E Schematics Wiring diagrams, hydraulic diagrams and list of electrical compo-

nents.
F Technical data Technical data, conversion tables, information for conversion of

units.
G Terminology and index General terminology and abbreviations, explanation of terms and
abbreviations that can appear in the sections, index for headings
in the manual.

Function group structure

page
–
The information in the manual is divided into a structure of functions at

different levels based on machine structure and usage. The categories
are known as function groups.
The highest level (called main group) indicates area, such as group 7
Load handling. The second level (called two-position) indicates func-
tion, such as 7.2 Lifting/lowering. The third and fourth levels are used
to break down functions into smaller parts (components).
The main group and two-position group level structure for the function
groups is used for all Kalmar Industries machines, e.g. 4.3 Power-as-
sisted brake system. Machine-specific function group adaptations are
done and the third and fourth group level, e.g. 4.3.9 Wheel brake and
4.3.9.1 Disc assembly. Function groups (headings) are only included
in the documentation of a machine if the machine has that function or
component. Thus, there may be gaps in function group numbering
(e.g. the three-position heading level 4.8.7 Oil cooler is included for
some machines but not for others).
The function groups are intended as a search term to be able to find
various types of information between different sections and manuals.
The information of a function group is divided into smaller segments
based on type of content, such as description or replacement.
The Maintenance Manual and Workshop Manual contain different in-
formation. The Maintenance Manual only contains information re-
quired for preventive maintenance and minor troubleshooting. The
Workshop Manual contains more in-depth information and repair in-
structions.
References between sections in the same manual are indicated using
section and group number, e.g., "see section 4 Brakes, group 4.3.9
Wheel brake ". Reference within a section are indicated with page
number, e.g., "see Sensor fuel level, description page 24 ".
There are no references between the Maintenance Manual and Work-
shop Manual. If more information on a function group is required,
search under the same function group in the other manual. For more
in-depth information on where different types of information are locat-
ed and what references are made, see References between different
information types page 7.

References between different information types

page
–
The maintenance manual and workshop manual are mainly divided

into function groups, see Workshop manual contents page 5. Certain
parts are broken out as separate parts to increase usability, e.g.,
"Technical data".
The basic rule of searching for information is to use function groups to
find different types of information regarding the function or component
in question. As a complement to this, there are references according
to the below.
Function descriptions Hydraulic diagrams

(Technical description) (Section E)
Component descriptions Error codes

(Technical description, usually in Workshop manual) (Section D)
Diagnostics Wiring diagrams

(Technical description, group 8.4) (Section E)
• From Function description to Component description, to enable

fast finding of more information about the different components
that create a function.
• From Function description to Hydraulic diagram, to enable fast
finding of the right hydraulic diagram for the function in question.
• From Component description or Function description to Diagnos-
tics, to enable fast finding of the right diagnostic menu that can be
used to check the component (only applies to electrical compo-
nents).
• From Diagnostics to Wiring diagrams. to enable fast finding of the
right circuit diagram for further troubleshooting.
• From Diagnostics to Component description or Function descrip-
tion. To enable fast finding of more information about the compo-
nent's appearance and position when troubleshooting.
• From Error codes to Diagnostics, to enable fast finding of the right
diagnostic menu to troubleshoot component or function in ques-
tion.
• From Error codes to Function description or Component descrip-
tion, to enable fast finding of more information about components
or function.

Product alternatives and optional equipment

page
–
The information in the manual is divided into modules. If a product al-

ternative or optional equipment is fitted, handling may differ from that
indicated in the modules depending on what is being described. See
below.
Special equipment is not described in the manual. If uncertain as to
what equipment is fitted to the machine, use the machine card to de-
termine which information is relevant. See Machine card page 8.
Product alternative
Product alternative describes options that are fitted instead of a spe-
cific piece of standard equipment (e.g. engine alternative).
Equivalent information for different product alternatives are described
consecutively in separate segments within the same function group.
To indicate that there are different alternatives, "Product alternative" is
added to the heading together with a simple description of the alterna-
tive, e.g. "(Product alternative Climate control system ECC)". In addi-
tion, the alternative that is an option is marked with the symbol for
optional equipment.
Optional equipment
000264
Optional equipment refers to options that can be added to standard

equipment for more or improved functions.
Symbol for optional equipment
Information on auxiliary equipment is described in separate segments
together with the standard equipment. The optional equipment de-
scription covers how the equipment affects standard function and what
components are added.
Machine card
page
–
NOTE
If the machine has been modified after delivery, information on
the machine card may be incomplete or incorrect.
The machine card indicates the drawings the machine consists of. In
many cases, these can be liked to option and product alternative. For
more information on handling product alternative and optional equip-
ment, see Product alternatives and optional equipment page 8. The
machine card is delivered with the spare parts catalogue.
The machine card is divided into the same function groups as the
spare parts catalogue, maintenance manual and workshop manual.
For reasons of practicality, the machine card only uses the first and
second level of the function group register. The function groups are
written in groups of four characters, e.g. group 0107 refers to group 1.7
Cooling system in the manual.
For more information on how the machine card is used to order spare
parts, see the foreword of the spare parts catalogue.
If the information on the machine card does not prove helpful, contact
Kalmar Industries AB.

NOTE
All documents that accompany the machine are non-registered
documents. No notification is made regarding changes.
Function descriptions
page
–
Function descriptions are schematic overviews that describe how a

function works as well as which components and signals work togeth-
er.
Function descriptions describe the function in a logical flow from input
signal to desired output signal. Most functions require that preset con-
ditions are fulfilled for the function to be activated. In these cases, the
conditions are listed above the illustration.
Function descriptions use symbols to illustrate components such as
valves, sensors, etc.
10 7 Lasthantering 7.2 Lyft och s nk
Lyft och s nk, funktionsbeskrivning (elservo)
F ruts ttning B rv rde H nvisning

Man verbrytare Frikopplad Flik 11 Gemensam el, grupp 11.5.1.4 Man verbrytarsp nning
5b
D5 1
5a
6
D790-1
D797-1
7
10 3
D7
10
9
C2
8
2 A 4
T H
P
C
P2
P1
10 2
T 9
9 C1
8
EF
P
1 1 T
8
3
009679
Pos F rklaring Signalbeskrivning H nvisning

1 Hydrauloljepumparna pumpar olja fr n Se tryckskylt p v nster Flik 10 Gemensam hydraulik, grupp 10.4.3
hydraultanken. rambalk. Vingspump med fast deplacement
2 Tryckreduceraren minskar tryck fr n hy- P = 3,5 MPa Tryckreducerare, beskrivning sida 17

drauloljepumpen till servotryck.
3 Ackumulatorn lagrar servotryck. Back- Se tryckskylt p v nster Ackumulator servokrets, beskrivning sida
ventilen i tryckreduceraren g r att tryck- rambalk. 15
et lagras n r motorn st ngs av.
4 Servofiltret renar oljan innan man ver- - Servofilter, beskrivning sida 19

7 ventil lasthantering. 4
6
010277
VDCF02.02SE Verkstadsmanual DCF 280-330, DCF 370-500
5
Example of function description

1. Flag diagnostics, indicates that the signal can be checked with a

diagnostic test; see group 8.4 Diagnostics
2. Hydraulic force (solid double line)
3. Illustration of function, (Lifting/lowering)
4. Reference to description of component
5. Signal description, reference value for signal out from component
6. Description of component's function
7. Position number, reference to position in illustration
8. Position number in illustration, reference to row in table
9. Flag pressure check connection (Check point), indicates that
there is pressure check connection for checking pressure signal
10. Electric power (solid single line)

Symbol explanation function descriptions

The following symbols are used in function descriptions, the symbols
1 2 are based on standard symbols used in wiring and hydraulic diagrams.
3 4 1. Electric control signal
2. Electric force
3. Hydraulic control signal
5 6
4. Hydraulic force
5. Hydraulic motor
6. Hydraulic oil pump with variable displacement
7 8 M 7. Hydraulic oil pump with fixed displacement
8. Electrical motor
9 10 9. Accumulator
10. Disc brake
11. Filter
11 12
12. Radiator
D790-1 13. Bulb
13 14 14. Control system, two control units with CAN-bus

D797-F 15. Restriction
16. Adjustable restriction
15 16
17. Inductive position sensor
17 18 18. Electrically controlled servo valve
19. Thermal bypass valve
19 ˚C 20 ˚C
20. Temperature-controlled switch
˚C Pa 21. Temperature sensor
21 22
22. Pressure sensor
23 Pa 24 23. Pressure-controlled switch
24. Hydraulic cylinder
25 25. Double-acting hydraulic cylinder
26. Spring brake cylinder
27. Valve block
26 27
28. Shuttle valve
29. Non-return valve
28 29
000523

12 A Foreword – About the documentation
About the documentation

Documentation sections
page
–
The documentation to the machine comprises the following sections:
Operator's manual
The Operator's manual is supplied with the machine in the cab.
Documentation kit
Maintenance manual and spare parts catalogue with machine card are
supplied with the machine as a separate documentation kit.
Supplementary documentation
Supplementary documentation can be ordered for the machine.
• Workshop manual.
• Supplier documentation for engine, transmission and drive axle.
Ordering of documentation
page
–
Documentation is available for order from Kalmar Industries dealers.

Always specify the publication number when ordering.
See the machine card for publication number.

A Foreword – Feedback 13
Feedback
Form for copying
page
–
Kalmar Industries’ ambition is that you who work with maintenance of

Kalmar machines shall have access to correct information.
Your feedback is important to be able to improve the information.
Copy this form, write down your views and send it to us. Thank you for
your participation!
To: Kalmar Industries AB

Product Support
Torggatan 3
SE-340 10 Lidhult
SWEDEN
Fax: +46 372 263 93
From:
Company / Sender: ..........................................................................................................................................
Telephone: ..........................................................................................................................................................
E-mail: .................................................................................................................................................................
Date: .................................... - .................. - ..................
Manual
informa- Name / Publication number: .............................................................................................................................
tion
Section / page number: ......................................................................................................................................
Sugges-
tions, .............................................................................................................................................................................
views, re-
marks,
etc. .............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................

14 A Foreword – Feedback

B Safety 1
B Safety
Table of Contents B Safety

mm mm mm mm mm mm
Safety .............................................................................................................. 3
General safety information ......................................................................... 3
Safety concerns everyone! ................................................................................ 3
A near accident is a warning! ............................................................................ 3
Safety instructions ...................................................................................... 4
General ............................................................................................................. 4
Service position ................................................................................................. 4
Hydraulic and brake systems, depressurizing ................................................... 5
Oils .................................................................................................................... 7
Fuel system ....................................................................................................... 8
Clothing, etc. ..................................................................................................... 9
Several mechanics on the same machine ......................................................... 9
Working under machine .................................................................................. 10
Lifting heavy components ............................................................................... 11
Vibrations ........................................................................................................ 11
Noise ............................................................................................................... 12
Solvents .......................................................................................................... 12
Fire and explosion risks ................................................................................... 13
Fluid or gas under pressure ............................................................................ 14
Coolant ............................................................................................................ 15
Refrigerant ...................................................................................................... 15
Air pollution ..................................................................................................... 16
Tensioned springs ........................................................................................... 17
Electric motors ................................................................................................. 17
Rotating components and tools ....................................................................... 17
Tyres and rims ................................................................................................. 18
Lifting equipment ............................................................................................. 19
Environment ............................................................................................. 20
General ........................................................................................................... 20

2 B Safety

B Safety – Safety 3
Safety
mm mm mm mm mm mm
General safety information

Safety concerns everyone!
page
–
The safety information concerns everyone who works with the ma-
chine! Persons who do not follow the safety instructions given in this
manual must make absolutely sure that the work is performed without
risks of personal injury and without risk of damage to machine or ma-
chine property!
Remember to:
• follow the instructions in this manual
• be trained for the work in question
• follow local laws, safety rules and regulations
• use the correct equipment and tools for the job
• wear the correct clothes
• use common sense and work carefully. Do not take any risks!
Kalmar Industries has in this publication documented and warned for
situations and risks that may occur in connection with using as well as
service/repairs of the machine during normal circumstances.
That’s why it’s important that all who work with the machine or repair/
service the machine read and follow the information in the workshop
manual and operator’s manual.
A near accident is a warning!

page
–
A near-accident is an unexpected event where neither persons, ma-

chine or property are injured or damaged. However, a near-accident
indicates that there is an injury risk and actions must be taken to avoid
the risk of injuries.

4 B Safety – Safety instructions
Safety instructions
General
page
–
Read, consider and follow the safety instructions below before starting
to work in the machine:
• Service position page 4
• Hydraulic and brake systems, depressurizing page 5
• Oils page 7
• Fuel system page 8
• Clothing, etc. page 9
• Several mechanics on the same machine page 9
• Working under machine page 10
• Lifting heavy components page 11
• Vibrations page 11
• Noise page 12
• Solvents page 12
• Fire and explosion risks page 13
• Fluid or gas under pressure page 14
• Coolant page 15
• Refrigerant page 15
• Air pollution page 16
• Tensioned springs page 17
• Electric motors page 17
• Rotating components and tools page 17
• Tyres and rims page 18
• Lifting equipment page 19
Service position
page
–
General
Service position is used for service, maintenance and other situations
when the machine needs to be secured.
Service position means:
• Machine parked, that is, parking brake applied.
• Forks and lifting carriage in fully lowered position.
• Engine off.
• Main electric power off (with battery disconnect switch).
007550
Machine with forks and lifting carriage in fully lowered

position

B Safety – Safety instructions 5
Hydraulic and brake systems, depressurizing

page
–
1 Make sure that the forks and the lifting carriage are fully lowered.
2 Depressurise the hydraulic system by draining servo pressure
from the accumulator.
007710
3
a) For hydraulic servo:
Repeatedly activate the load handling functions.
b) For electric servo:
Turn the main current on, turn the starter key to position I and
activate the load handling functions several times.
4 Turn the start key to position 0 and turn off the main electric pow-
er.

5 Depressurise the brake system by opening the drain valve on the

accumulator charging valve.
NOTE
Keep the drain valve open as long as work is in progress.
When closing the drain valve, check that it is fully closed and
tighten the lock ring.
005648

Oils
page
–
The following safety instructions shall be followed for work when hand-
ling oils.
WARNING
Warm and pressurized oil.
Always depressurise hydraulic and brake systems

completely before starting to work in the systems. Hy-
draulic and brake systems are pressurised and the oil
may cause personal injuries.
Avoid skin contact with the oil, use protective gloves.

Warm oil can cause burn injuries, rashes and irrita-
tion! The oil may also be corrosive to mucous mem-
branes in, e.g., the eyes, skin and throat.
IMPORTANT
Always clean the area around components and con-
nections before they are loosened. Dirt in oil systems
causes increased wear, resulting in subsequent ma-
terial damages.
Always take action to avoid spills. In places where

drain containers cannot be used, use a pump or hose
for safe handling.
Always check that plugs seal tight before collection

containers are moved.
Handle all oil as environmentally hazardous waste.

Oils freely released cause damage to the environment
and may also cause fires. Waste oils/fluids shall al-
ways be handled by an authorized company.

Fuel system
page
–
The following safety instructions shall be followed for work when hand-
ling fuel.
DANGER
Pay attention to the risk of fire when working on the
fuel system.
Work on the fuel system shall be avoided when the

engine is warm since fuel can spill on hot surfaces
and may ignite.
WARNING
Use protective gloves and protective goggles. If a
component is to be disconnected, hold a rag over the
connection as protection and to collect fuel. The en-
gine’s fuel system operates at very high pressure.
The pressure is so high that the jet can injure the skin,
resulting in severe injuries. Risk of personal injuries.
Avoid skin contact with fuel, use protective gloves.

Fuel is corrosive to mucous membranes in, e.g., eyes,
skin and throat.
CAUTION
Always clean the area around components and con-
nections before they are loosened. Dirt in the fuel may
cause malfunctions and engine stop in undesirable
situations as well as increase wear, resulting in sub-
sequent material damages.

IMPORTANT
Always take action to avoid spills. In places where
drain containers cannot be used, use a pump or hose
for safe handling.
Always check that plugs and connections seal tight

before moving collection containers.
Handle the fuel as environmentally hazardous waste.

Fuel freely released causes damage to the environ-
ment and may also cause fires. Fuel shall always be
handled by an authorized company.
Clothing, etc.
page
–
Clothes should be in good condition. Remove loosely hanging clothing

(tie, scarf, etc.). Do not wear clothes with wide sleeves, wide trouser
legs, etc.
Remove jewellery as it may conduct electricity and get caught in mov-
ing parts.
Long hair must be tied up securely, otherwise it may easily get caught
in moving parts. Be careful when performing welding work or work re-
quiring open flames since hair catches fire easily.
Several mechanics on the same machine

page
–
WARNING
If several mechanics are working on the same vehicle,
take extra care so that unintentional movements do
not injury another person. Communicate so that eve-
ryone knows where all are and what they are doing.
Risks
Work with wheels or axle suspension, mountings, etc. may result in
components on the other side moving and causing damage/injury.
Movements performed from the operator's station, e.g., movement of
lifting equipment, may cause severe personal injuries.

Safety precautions
• Make sure that the machine's lifting equipment is completely low-
ered or secured in another way.
• Move battery disconnector to position zero, remove the key.
• Be aware of the risks when several persons work around the ve-
hicle.
• Make your co-workers aware of what you’re working with.
• Do not work with drive wheels on the machine's both sides at the
same time.
Working under machine

–
page
Working under cab

There must not be any unsecured objects in the cab when tipping.
The cab must always be tipped to its end position and secured with a
stopping device.
If the work requires that the cab not be tipped to its end position or if
working on the cab suspension, the cab must always be secured with
a stopping device.
Work under chassis

A raised vehicle may not, for any reason, be supported or lifted in parts
that belong to the wheel suspension or steering. Always support under
the frame or wheel axle.
Risks
Mechanical or hydraulic tools and lifting devices can fall over or acci-
dentally be lowered due to malfunctions or incorrect use.
Safety precautions
Use axle stands and supports that stand securely.
Lifting tools should be inspected and type approved for use.

Lifting heavy components

page
–
WARNING
Careless handling of heavy components can lead to
serious personal injury and material damage.
Use type approved lifting tools or other devices to

move heavy components. Make sure that the device is
stable and intact.
Risks
Unsuitable lift slings, straps, etc. may break or slip.
The centre of gravity (balance point) of the component can change
during the course of the work, and the component may then make un-
expected movements which may cause severe personal injuries and
material damage.
A component lifted with lifting equipment can start to turn if the equilib-
rium is upset.
A component lifted using an overhead crane may start to swing back
and forth, which can cause severe crushing injuries or material dam-
age.
Safety precautions
Lifting with lifting device. Use lifting tools or other tools, especially
when there are such adapted for certain work. See workshop manual
for methods.
If lifting must be performed without lifting device:
• Lift near the body.
• Keep your back vertical. Raise and lower with legs and arms, do
not bend your back. Do not rotate your body while lifting. Ask for
assistance in advance.
• Wear gloves. They're good protection against minor crushing in-
juries and cuts to fingers.
• Always use protective shoes.
Vibrations
page
–
In case of long-term use of vibrating tools, for example, impact nut run-
ners or grinders, injuries may be sustained as vibrations can be trans-
mitted from tools to hands. Especially when fingers are cold.
Safety precautions
Use heavy gloves to protect against cold and somewhat against vibra-
tions.
Switch between work duties to give the body time to rest.
Vary work position and grip so that the body is not stressed in only one
position by the vibrations.

Noise
page
–
Noise louder than 85 dB (A) that lasts for longer than 8 hours is con-
sidered harmful to hearing. (Limit values may vary between different
countries.) High tones (high frequencies) are more damaging than low
tones at the same sound level. Impact noise can also be hazardous,
e.g. hammer blows.
Risks
At noise levels higher than the limits hearing damage can occur. In
more severe cases, hearing damage can become permanent.
Safety precautions
Use hearing protection. Make sure that it is tested and protects against
the noise level in question.
Limit noise with noise-absorbing dividers, for example, noise-absorb-
ing materials in roof and on walls.
Solvents
page
–
Fluids that (as opposed to water) dissolve grease, paint, lacquer, wax,
oil, adhesive, rubber, etc. are called organic solvents. Examples:
White (petroleum) spirits, gasoline, thinner, alcohols, diesel, xylene,
trichloroethylene, toluene. Many solvents are flammable and consti-
tute a fire hazard.
Risks
Products containing solvents produce vapours that can cause dizzi-
ness, headaches and nausea.They may also irritate mucous mem-
branes in the throat and respiratory tracts.
If the solvent comes into direct contact with the skin, this may cause
drying and cracking.Risk for skin allergies increases. Solvents may
also cause injury if they penetrate through the skin and are absorbed
by the blood.
If the body is continuously exposed to solvents, the nervous system
may be damaged. Symptoms include sleep disorders, depressions,
nervousness, poor memory or general tiredness and fatigue. Continu-
ous inhalation of gasoline and diesel fumes is suspected to cause
cancer.
Safety precautions
Avoid inhaling solvent fumes by providing good ventilation, or wearing
a fresh-air mask or respiratory device with a suitable filter for the toxic
gases.
Never leave a solvent container without tight-sealing lid.
Use solvents with low content of aromatic substances. This reduces
the risk of injuries.
Avoid skin contact.
Use protective gloves.
Make sure that work clothes are solvent-resistant.

Fire and explosion risks

page
–
Examples of flammable and explosive substances are oils, gasoline,

diesel fuel oil, organic solvents (lacquer, plastics, cleaning agents),
rustproofing agents, welding gas, gas for heating (acetylene), high
concentration of dust particles consisting of combustible materials.
Rubber tyres are flammable and cause explosive fires.
Risks
Examples of cause of ignition is welding, cutting, smoking, sparks
when working with grinders, contact between hot machine parts and
flammable materials, heat development in rag drenched with oil or
paint (linseed oil) and oxygen. Oxygen cylinders, lines and valves shall
be kept free from oil and grease.
Fumes from, e.g., gasoline are heavier than air and may "run" down
into a sloping plane, or down in a grease pit, where welding flames,
grinding sparks or cigarette embers may cause an explosion. Evapo-
rated gasoline explodes very forcefully.
Special cases
Diesel fuel oil with added gasoline has a lower ignition point. Risk of
explosion already at room temperature. The explosion risk for warmed
diesel fuel oil is higher than for gasoline.
When changing oil in the engine, hydraulic system and transmission,
keep in mind that the oil may be hot and can cause burn injuries.
Welding on or near machine. If diesel and or other oils have leaked out
and been absorbed by rags, absorbent agents, paper or other porous
material, hot welding sparks can cause ignition and explosive fires.
When a battery is charged, the battery fluid is divided into oxygen and
hydrogen gas. This mixture is very explosive. The risk of explosion is
especially high when using a booster battery or quick-charger, as this
increases the risk of sparks.
Today’s machines contain a lot of electronic equipment. When weld-
ing, the control units must be disconnected and the electric power
must be turned off with the battery disconnect switch. Powerful weld-
ing currents may otherwise short-circuit the electronics, destroy ex-
pensive equipment or cause an explosion or fire.
Never weld on painted surfaces (remove paint, by blasting at least 10
cm around the welding or cutting point). Use gloves, breathing protec-
tion and protective goggles. In addition, welding work may not be done
near plastic or rubber materials without first protecting them from the
heat. Paints, plastics, and rubber develop a number of substances that
may be hazardous to health when heated. Be careful with machines
that have been exposed to intense heat or fire.

Safety precautions
Store hazardous substance in approved and sealed container.
Make sure that there is no ignition source near flammable or explosive
substances.
Make sure that ventilation is adequate or there is an air extraction unit
when handling flammable substances.
Fluid or gas under pressure

page
–
High-pressure lines can be damaged during work, and fluid or gas can
stream out.
There may be high pressure in a line even if the pump has stopped.
Therefore, gas or fluid can leak out when the connection to the hose
is loosened.
A gas cylinder subjected to careless handling can explode, for exam-
ple, if it falls onto a hard surface. Gas can stream out through dam-
aged valves.
Risks
There are injury risks in connection with work on:
• Hydraulic systems (e.g., working hydraulics and brake system).
• Fuel system.
• Tyre changes.
• Air conditioning.
Safety precautions
• Use safety glasses and protective gloves.
• Never work on a pressurized system.
• Never adjust a pressure limiting valve to a higher pressure than
recommended by the manufacturer.
• A hydraulic hose that swells, for example, at a connection, is
about to rupture. Replace it as soon as possible! Check connec-
tions thoroughly.
• Use fluid when checking for leaks.
• Never blow clothes clean with compressed air.
• Discarded pressure accumulators must first be punctured before
they are deposited as waste (to avoid risk of explosion). Carefully
drill a hole with 3 mm diameter after depressurizing.
• Never use your hands directly to detect a leak. A fine high-pres-
sure stream from a hydraulic hose can easily penetrate a hand
and causes very severe injuries.

Coolant
page
–
The coolant in the machine’s cooling system consists of water, anti-

corrosion compound and (when needed) anti-freeze fluid, for example,
ethylene glycol.
Coolant must not be drained into the sewer system or directly onto the
ground.
Risks
The cooling system operates at high pressure when the engine is
warm. Hot coolant can jet out and cause scalding in case of a leak or
when the expansion tank cap (filler cap) is opened.
Ingesting ethylene glycol and anti-corrosion compound is dangerous
and hazardous to health.
Safety precautions
• Use protective gloves and safety glasses if there is a risk of
splashing or spraying.
• Open the filler cap first, to release the excess pressure. Open
carefully.Hot steam and coolant can stream out.
• If possible, avoid working on the cooling system when the coolant
is hot.
Refrigerant
page
–
Refrigerant is used in the machine’s air conditioning system.

Work on the air conditioning system must be performed by accredited/
authorized and trained personnel according to national legislation and
local regulations.
Risks
The air conditioning operates at high pressure. Escaping refrigerant
can cause frostbite.
Refrigerant that is heated (e.g., when repairing leaking climate/AC
system), generates gases that are very dangerous to inhale.
Safety precautions
• When working on the air conditioning system, use the special in-
structions and equipment for refrigerant specified in the workshop
manual. Anyone performing such work must have special certifi-
cation and authorization. (Note national legislation and local reg-
ulations!)
• Use protective gloves and safety glasses if there’s a risk of leaks.
• Make sure that heat-producing sources or objects are not close by
(cigarette glow, welding flame).

Air pollution
page
–
Air pollution is the impurities in the air around us and which are regard-
ed as hazardous to health. Certain pollution is more prominent in cer-
tain environments.
The following health-hazardous air pollution is especially prominent in
workshops:
• Carbon monoxide (fumes) is present in exhaust fumes. Odour-
less and therefore especially dangerous.
• Nitrogen oxides (nitrous gases) are present in exhaust fumes.
• Welding smoke especially hazardous to health when welding on
oily surfaces, galvanized or lacquered materials.
• Oil mist for example, when applying anti-corrosion agent.
• Grinding dust and gases generated when grinding and heating
plastics, lacquer, anti-corrosion agents, lubricants, paint, etc.
• Isocyanates are present in certain paints, fillers, adhesives and
foam plastics used on machines.
Risks
Sulfuric acid mist is corrosive and injures the respiratory tracts. (Gen-
erated when heating certain plastics and paints.)
Isocyanates can be released in the form of steam, dust (or may be
present in aerosols) when cutting, grinding or welding. Can irritate mu-
cous membranes producing symptoms similar to asthma and impair-
ing lung function. Even brief exposure to high concentrations can give
problems with persistent high sensitivity.
Safety precautions
• Make sure of adequate ventilation with fresh air when welding,
battery charging and other work when hazardous gases are gen-
erated.
• Use suitable protective gloves and breathing protection when
there is a risk of oil mist. Make sure that the protection is oil-proof.
• Apply oil-resistant protective lotion to unprotected skin.
• Make sure that an eye-wash station is in the immediate vicinity
when working with corrosive substances.
• Avoid unnecessary operation of the machine inside the workshop.
Connect an air extractor to the exhaust pipe so that the exhaust
fumes are removed from the workshop.

Tensioned springs
page
–
Examples of tensioned springs:

1. Torque springs in pedals for example
2. Return spring (cup springs) in parking brake cylinder.
3. Lock rings
4. Gas springs
Risks
If a tensioned spring releases, it is shot out by the spring force and can
also take adjoining parts with it.
Small springs can cause eye injuries.
Parking brake springs are tensioned with high force and can cause
very severe accidents if they are accidentally released in an uncon-
trolled manner.
Gas springs and gas-charged shock absorbers are tensioned with
high force and can cause very severe accidents if they are accidentally
released in an uncontrolled manner.
Safety precautions
• Use safety glasses.
• Lock rings should be of a suitable type and in good condition.
• Follow the instructions in this and other manual when performing
maintenance and changing parts and components.
• Always use recommended tools.
Electric motors
page
–
Safety precautions
Always turn off the battery disconnector when working on electric mo-
tors.
Always block the machine’s wheels and make sure that the parking
brake is activated and that the gear selector is in neutral position be-
fore starting any work on the machine.
Rotating components and tools

page
–
Examples of rotating components and tools:

• Cooling fan
• Drive belts
• Propeller shafts
• Drills
• Grinders
Risks
Rotating components, for example, fans or shafts, can cause severe
injuries if touched.

Drills, lathes, grinders or other machines with rotating parts can cause
severe accidents if clothes or hair get caught and are wound up in the
machine.
Safety precautions
• Do not use gloves when working with a drill.
• Remove loose, hanging clothing, scarf or tie.
• Never use clothing with wide sleeves or trouser legs.
• Make sure that clothing is intact and in good condition.
• Long hair should be gathered up in a hair-net or similar.
• Remove large or loose hanging jewellery from hands, arms and
neck.
Tyres and rims

page
–
DANGER
Tyres should be regarded as pressurized containers.
They constitute fatal danger if handled incorrectly.
Parts can be thrown with explosive force and may

cause severe injuries.
Never repair damaged tyres, rims or lock rings. Tyre

changes shall be performed by authorised personnel.
Risks
Dismantling wheels: Tyres, rims or lock rings can be thrown.
Inflating of wheels: Tyres, rims or lock rings may be ejected.
Safety precautions
• Deflate the tyre before starting to work on the wheel.
• Check that tyres, rims and lock rings aren’t damaged. Never re-
pair damaged rims or lock rings.
• Wheels shall be inflated on the machine or in a protective device,
designed and dimensioned so that it can handle or dissipate a
shock wave from a tyre explosion as well as catch the ejected
parts.
• Use protective screen and safety glasses.

Lifting equipment
page
–
When working on the machine in general, and with the lifting equip-
ment in particular, the greatest caution must be exercised with respect
to securing the mast and carriage.
Always make a habit of lowering the carriage to its lowest position be-
fore working on the machine.
Risks
Risk of crushing if the machine’s lifting equipment is not lowered or se-
cured.
Risk of crushing is extra high when depressurising the hydraulic sys-
tem; see Hydraulic and brake systems, depressurizing page 5.
Safety precautions
• Do not start work until the carriage is completely lowered. If by na-
ture the work requires a raised carriage, this must be secured.

20 B Safety – Environment
Environment
General
page
–
Ever-increasing industrialisation of our world is having a significant im-

pact on our global environment. Nature, animals and man are subject-
ed daily to risks in connection with various forms of chemical handling.
There are still no environmentally safe chemicals, such as oils and
coolants, available on the market. Therefore, all who handle, perform
service on or repair machines must use the tools, assisting devices
and methods necessary to protect the environment in an environmen-
tally sound manner.
By following the simple rules below, you will contribute to protecting
our environment.
Recycling
Well-thought out recycling of the machine is the cornerstone of ending
its life cycle and being able to reuse materials in new products. Ac-
cording to calculations by Kalmar Industries, the machine can be recy-
cled to more than 90% by weight.
Environmentally hazardous waste

Components such as batteries, plastics, and other materials that may
be considered as environmentally hazardous waste must be handled
in an environmentally correct manner.
Discarded batteries contain substances hazardous to personal health
and the environment. Therefore, handle batteries in an environmental-
ly safe manner and according to national regulations.
Oils and fluids

Oils freely discharged cause environmental damage and can also be
a fire hazard. Therefore, when emptying and draining oils or fuel, take
appropriate action to prevent unnecessary spills.
Waste oils and fluids must always be taken care of by an authorized
disposal company.
Pay close attention to oil leaks and other fluid leaks! Take immediate
action to seal the leaks.
Air conditioning unit

The refrigerant in the air conditioning unit for the cab contributes to the
greenhouse effect and may not be intentionally released into the open
air. Special training is required for all service work on the air condition-
ing unit. Many countries demand certification by a governing authority
for such work.
Working in a contaminated area

The machine shall be equipped for work within a contaminated area
(environmental contamination or health-hazardous area) before work
is started. Also, special local regulations apply to such handling and to
service work on such a machine.

B Safety – Environment 21
Declarations
The machine does not contain asbestos.
The machine contains lead in batteries and electric cabling. Some
models have counterweights of cast lead.
If the machine is equipped with air conditioning, then refrigerant of the
type R134a is used, in an amount between 1-3 kg.

22 B Safety – Environment

C Preventive maintenance 1
mm mm mm mm mm mm
Preventive maintenance
page
–
See Maintenance manual DCF 280-500, section C Preventive mainte-

nance.

2 C Preventive maintenance – C Preventive maintenance

0 Complete machine 1
0 Complete machine
Table of Contents 0 Complete machine

mm mm mm mm mm mm
Complete machine ......................................................................................... 3

Complete machine, description ............................................................................. 3
Troubleshooting, general work instructions ............................................................ 4
Troubleshooting without an error code, example ................................................... 5
Troubleshooting with error code, example ............................................................. 6
Troubleshooting cable harness .............................................................................. 7
Troubleshooting hydraulic hoses ............................................................................ 8

2 0 Complete machine

0 Complete machine – Complete machine 3
Complete machine
mm mm mm mm mm mm
Complete machine, description

page
–
The Kalmar DCF 280-500 is a forklift truck with a lifting capacity of 28–
50 tons depending on version.
The power source is a straight 6-cylinder, 4-stroke turbocharged low-
emission diesel engine with unit injectors and air-to-air intercooler.
The transmission is hydromechanical with gears in constant mesh. It
has three or four gears in each direction, depending on version. En-
gine power is transferred with a torque converter.
The driveline/axle comprises a propeller shaft and a rigid drive axle
with hub reduction. Drive is via the front wheels.
The service brake is of wet disc type, built together with drive wheel
hubs. The parking brake is a disc brake and acts on the drive axle in-
put shaft.
Steering is via the rear wheels and a double acting hydraulic cylinder.
The steering axle is pendulum-suspended in the frame.
The wheels are mounted on the hubs with clamps. Twin wheels are
mounted on the drive axle, while the steering axle has single wheels.
Load handling comprises components and functions for handling
loads. The load is lifted with forks that are secured at a carriage and
sit on a mast. Load handling comprises the functions lifting/lowering,
tilt, side shift, spreading, levelling and load carrier.
• Lifting/lowering is the function used to raise and lower the fork
carriage.
• Side shift is moving the forks parallel at the same distance from
each other laterally along the carriage.
• Spreading is adjusting the width between the forks on the
carriage.
• Tilt is used to angle the load in the longitudinal direction of the ma-
chine with the help of the mast.
• Levelling is angling the load in the lateral direction of the machine.
• Load carrier is holding or gripping the load.
The control system is functions for warning the operator of dangerous
situations and machine faults. The control system has diagnostic re-
sources that simplify troubleshooting.
The frame bears the machine. The frame houses the engine, trans-
mission, drive axle and steering axle. The sides of the frame house
tanks for fuel, hydraulic oil and brake system fluid. The cab is posi-
tioned centrally. As an option, the cab can be displaced laterally.

4 0 Complete machine – Complete machine
Troubleshooting, general work

page
–
instructions
When troubleshooting, it is important that the work is structured and
logical. The point of the troubleshooting described in the maintenance
manual is to exclude components as error source so that the real error
source can be pin-pointed. A suggested structured work method is de-
scribed below.
When troubleshooting, it is important to understand how the machine
functions. Certain malfunctions can be pin-pointed directly using func-
tion descriptions. Sections 0–12 contain descriptions of the various
functions of the machine.
Troubleshooting procedure
1 Check that there is battery voltage available.
• Battery disconnect switch, must be in position 1.
• Battery voltage, should be 22–30 V.
• Fuses, check that they are intact.
2 Check that all oil and fluid levels are normal.
• Fuel
• Engine oil
• Transmission oil
• Brake system fluid

• Hydraulic oil
• Coolant
• Washer fluid
3 Check if there are error codes.
4 If there are error codes, use the error code lists as a guide. See
Troubleshooting with error code, example page 6.
In the error code lists there are recommended actions for every
error code. Error code lists are found in section D Error codes.
5 If there is no error code or the problem persists, use the function
description for the function in question in section 0–12.
The function description contains information on which compo-
nents are involved in the function and how these components
work together. In some cases, there is information on what con-
ditions are required in order for it to be possible to activate the
function. Measurement points are marked with flags (C as in
checkpoint for measuring outlet, D for diagnostic menu).

Troubleshooting without an error

page
–
code, example
1 Choose suitable section 0–12 to find the function and sub-func-
tion that have caused the symptom.
2 Read the function description for the function in question to get
an overall understanding of which components are affected and
how these interact.
3 Use the function description and check the signals for the func-
tion in question to find where in the function chain that signal or
reaction is incorrect.
4 The fault is probably between the two units where the signal is
failing. Start by checking the component that should send the
signal.
5 If the component that is to send the signal seems to be correct,
check transmission of the signal (electric wiring or hydraulic
hoses).
For electric cabling, see Troubleshooting cable harness page 7.
For hydraulic hoses, see Troubleshooting hydraulic hoses page
8.
6 If the leads or hoses between the components seem in order,
then check the component that receives the signal.

Troubleshooting with error code,

page
–
example
Error codes are strong indicators of malfunctions detected by the con-
trol system. Many error codes are connected to electrical malfunctions
but there are also error codes that interpret associations between one
or several signals that indicate a non-electrical malfunction. It’s impor-
tant to not draw conclusions too fast based on an error code.
1 Read out error codes from the display, e.g., error code 34.
2 Use the error code lists and search information about the error
code, see "Example of error code information in error code list"
below.
Error code lists are found in section D Error codes.
For detailed instruction on reading out error code, see section D
Error codes.
3 Follow the instructions in the field “Action”.
4 Use diagnostic menus and circuit diagrams to determine if the in-
put signal to the control unit is correct; see section 8 Control sys-
tem, group 8.4 Diagnostics as well as section E Schematics.
5 Use the function group to find more information if needed.
In section 0–12 there is function description, the function's includ-
ed components and their position as well as, in certain cases,
work instructions for how components are checked, cleaned or
adjusted.
6 If possible, eliminate component fault by testing the component
individually.
Electric components can sometimes be checked with resistance
measurements using a multimeter.
Hydraulic components are often checked by measuring pressure
(then described in the function group and indicated in the section
C Preventive maintenance). Sometimes valves can be activated
mechanically to determine if the malfunction is electric or hydrau-
lic.
7 If the component’s measurement values are correct, continue by
troubleshooting electric cables and hydraulic hoses.
For electric cabling, see Troubleshooting cable harness page 7.
For hydraulic hoses, see Troubleshooting hydraulic hoses page
8.
8 If the cable is not defective, then connect the lead to the control
unit.
NOTE
The main electric power shall be turned off with the battery
disconnector!
9 Disconnect the cable from the component in question.
10 Turn on the main electric power with the battery disconnect
switch.

11 Turn the ignition key to the operating position.

12 Check that voltage reaches the component.
Table 1. Example of error code information in error code list
Connec-
tions and Diagnostic Function
Code Description Limitation Action
compo- menu group
nents
34 Signal error from Parking brake Check cabling be- D790-1/K8:5 - HYD, menu 5 4.1.2 Parking
parking brake cannot be re- tween the control unit S107, K8:13 - brake control
switch, indicates released. and the component S107
leased and applied with diagnostic menu.
at same time or noth- Check component.
ing at all.
Troubleshooting cable harness

page
–
NOTE
Perform troubleshooting for all cables in the same way to avoid
damage to control units, components or measuring equipment.
1 Study the circuit diagram in question, check where the suspected

cable is connected and if, and if so where, it is spliced.
2 Turn off the main electric power with the battery disconnect
switch.
3 Unplug the connector at the control unit or component in ques-
tion.
4 Check if there is open circuit.
NOTE
Some components cannot be checked without power supply
to the component. In such an event, proceed to point 5.
a. Measure resistance between connections for the component
in the connector at the control unit or component.
b. The resistance must correspond with the component. Other-
wise there may be an open circuit or short circuit in cable har-
ness and/or component.
5 Check if there is short circuit to frame:
a. Unplug the connector at both the control unit and the compo-
nent in question.
b. Measure the resistance of one lead at a time. Measure be-
tween the lead and a frame-connected part of the machine.
c. The multimeter should show endless resistance.

Troubleshooting hydraulic hoses

page
–
WARNING
Oil under high pressure!
Personal injury!
Always depressurize hydraulic and brake systems

before starting to work on the systems.
1 Depressurise the hydraulic and brake systems; see section B

Safety.
2 Study the relevant hydraulic diagram, check between whichever
components the suspect hose is connected and correspondingly
where it is spliced.
3 Locate the hose on the machine.
Start at one component and follow the hose to the next compo-
nent.
4 Inspect the entire hose and splicing points with respect to chafing
damage, pinching damage and leaks.
Change damaged hoses. When removing a hydraulic hose,
change of O-ring is always recommended on the hoses that have
these (ORFS).

1 Engine 1
1 Engine
Table of Contents1 Engine

mm mm mm mm mm mm
1 Engine ............................................................................................................. 3
1.1 Controls and instruments ......................................................................... 43
1.1.1 Ignition switch ...................................................................................... 43
1.1.2 Accelerator pedal ................................................................................. 44
1.2 Fuel system .............................................................................................. 45
1.2.1 Fuel tank .............................................................................................. 45
1.2.2 Sensor, fuel level ................................................................................. 45
1.6 Air intake and exhaust outlet .................................................................... 46
1.6.1 Air cleaning system .............................................................................. 46
1.6.3 Exhaust system ................................................................................... 47
1.6.4 Intercooler ............................................................................................ 48
1.7 Cooling system ......................................................................................... 49
1.7.4 Radiator and expansion tank ............................................................... 50
1.7.5 Cooling fan ........................................................................................... 51
1.7.7 Coolant ................................................................................................ 55
1.7.8 NO (normally open) switch, coolant level ............................................ 60
1.7.10 Engine heater ...................................................................................... 60
1.9 Control system engine .............................................................................. 61
1.9.1 Control unit, engine .............................................................................. 61
1.11 Start/stop .................................................................................................. 62
1.11.1 Starter motor ........................................................................................ 62
1.11.2 Stopping device ................................................................................... 62

2 1 Engine

1 Engine – 1 Engine 3
1 Engine
mm mm mm mm mm mm
Engine, general
page
–
Engine alternative
The following engine alternatives can be used with DCF 280-330:
• Cummins QSB6.7 (194 kW) , (stage III as per 97/68/EC direc-

tive)
• Volvo TAD760VE (181 kW), (stage III as per 97/68/EC directive)
The following engine alternatives can only be used with DCF 330:
• Volvo TAD950VE (210 kW) , (stage III as per 97/68/EC direc-

tive)
The following engine alternatives can be used with DCF 370-500:
• Volvo TAD952VE (252 kW), (stage III as per 97/68/EC directive)
• Volvo TAD1250VE (247 kW) , (stage III as per 97/68/EC di-

rective)
• Cummins QSM11 (261 kW) , (stage III as per 97/68/EC direc-

tive)
If there are differences between engine alternatives, this is written in
brackets after headings or under figures to clarify that which is shown.
NOTE
Certain aspects of Volvo and Cummins engines are the same. In-
structions common to the two are indicated (Volvo or Cummins
engine). If the instructions are unique, the entire engine designa-
tion is specified.
Component supplier documentation

The workshop manual only describes components and job descrip-
tions related to installation in the machine. Please refer to the compo-
nent supplier documentation for descriptions and instructions of the
engine components and systems.
References to supplier documentation are only used as an exception.
If there is no information about a component, use the supplier docu-
mentation.

4 1 Engine – 1 Engine
Machine electrical components,

page
–
location
3 4 5
0
P I
2 II
III
6a
6b
009623
11 10 9 8 7
Machine electrical components
1. Accelerator pedal (B690) 6b.

Control unit, Cummins engine (D794)
2. Ignition switch (S150) 7. Transmission control unit (D793)
3. KIT cab control unit (D790-2) 8. Fuel tank
4. Control unit KID (D795) 9. Fuel level sensor (B757)
5. Control unit cab (D790-1) 10. Frame control unit (D797-1)
6a. Control unit, Volvo engine (D794)
11. Frame option control unit (D797-2)

Engine, function description

page
–
(Volvo TAD760VE engine)

Volvo TAD760VE is a straight 6-cylinder, 4-stroke turbocharged low-
emission diesel engine with unit injectors, common rail technology and
air-to-air intercooler.
Condition Reference value Reference

Disconnected (when cable is in start lock-out is activated). Engine heater, description page 60
Engine heater
˚C
. bar
0 rpm
P I kph
II
III
D5
<˚
1,5
10
D10
D1
D14 D11
3,12,14,23 11,22 2,6
D794 D790-1 D790-2
D7
D793 D797-1 D795
D19 20 17 15,18,21
D16
D12
19 D4 H2O
SENSORS D8
4 13 16
9
009685
8 M 7
The illustration depicts the function description for Volvo TAD760VE.
Pos Explanation Signal description Reference

1 The ignition switch (S150) sends a U = 24 V Ignition switch function page 43
voltage signal to the cab control unit D1: Diagnostic menu, see section 8 Control sys-
(D790-1) when the start key is turned tem, group 8.4.1.5 CAN/POWER, menu 5 and
to position 1 or the preheating posi- 8.4.6.4 ENGINE, menu 4
tion.
2 Cab control unit KIT (D790-2) sends Checked by control sys- See section 11 Common electrics, group
ignition on via the CAN bus. If the key tem, error shown with error 11.5.3.11 Control unit KIT (D790-2)
is turned to the preheating position, code.
then preheating is also sent on the
CAN bus.


3 If preheating has been activated with U = 24 V Se Engine control unit, general page 61
the start key or automatically, then the
engine control unit (D794) feeds volt-
age to the preheating relay and
through this also the preheating coils
(E800-1).
4 The preheating coils (E800-1) warm - D4: Diagnostic menu, see section 8 Control sys-
each cylinder with a glow plug. tem, group 8.4.6.5 ENGINE, menu 5

voltage signal to the KIT control unit D5: Diagnostic menu, see section 8 Control sys-
(D790-2) when the start key is turned tem, group 8.4.6.4 ENGINE, menu 4
to start position.
6 Control unit KIT (D790-2) transmits a - See section 11 Common electrics, group
start signal on the CAN bus. 11.5.3.11 Control unit KIT (D790-2)
7 The starter motor (M654) is controlled U = 24 V Starter motor, description (Volvo engine) page 62
by the engine control unit (D794) D7: Diagnostic menu, see section 8 Control sys-
through starter relays and receives tem, group 8.4.6.5 ENGINE, menu 5
signals from the cab control unit
(D790-1) via the CAN bus.
8 The starter motor (M654) cranks the - Starter motor, description (Volvo engine) page 62
engine. D8: Diagnostic menu, see section 8 Control sys-
tem, group 8.4.6.5 ENGINE, menu 5
9 The engine’s sensors send signals to - Se Engine control unit, general page 61
the engine control unit (D794), which
regulates the injectors so that the en-
gine starts.
10 The accelerator pedal (B690) sends U = 0.5–4.5 V See section 11 Common electrics, group 11.5.3.1
the cab control unit (D790-1) a voltage Lower voltage than 0.5 V Cab control unit (D790-1)
signal proportional to the downward and higher voltage than 4.5 D10: Diagnostic menu, see section 8 Control sys-
press of the pedal. V used to detect malfunc- tem, group 8.4.6.1 ENGINE, menu 1
tion in cable harnesses and
controls.
11 The cab control unit (D790-1) trans- Checked by control sys- See section 11 Common electrics, group 11.5.3.1
mits a message with the rpm request tem, error shown with error Cab control unit (D790-1)
on the CAN bus code. D11: Diagnostic menu, see section 8 Control sys-
12 The engine control unit (D794) in- - Se Engine control unit, general page 61
creases engine speed. D12: Diagnostic menu, see section 8 Control sys-
13 The NO switch for coolant level U = 24 V NO (normally open) switch, coolant level page 60
(B759) sends a voltage signal to the
engine unit (D794) if the coolant level
in the expansion tank is low.


14 The engine control unit (D794) trans- Checked by control sys- Se Engine control unit, general page 61
mits engine data and warning mes- tem, error shown with error D14: Diagnostic menu, see section 8 Control sys-
sages on the CAN bus. code. tem, group 8.4.6.6 ENGINE, menu 6, 8.4.6.7 EN-
GINE, menu 7 and 8.4.6.8 ENGINE, menu 8
15 The KID control unit (D795) shows en- - Section 9 Frame, body, cab and accessories,
gine data via display figures. group 9.1 Controls and instruments
16 The fuel level sensor (B757) sends R = 0–70 ohm Sensor, fuel level, description page 45
the frame control unit (D797-1) a volt- D16: Diagnostic menu, see section 8 Control sys-
age signal proportional to the fuel lev- tem, group 8.4.3.7 CAB, menu 7
el in the tank.
17 The frame control unit (D797-1) trans- Checked by control sys- See section 11 Common electrics, group 11.5.3.2
mits fuel level on the CAN bus. tem, error shown with error Frame control unit (D797-1)
code.
18 The KID control unit (D795) shows - See section 11 Common electrics, group
fuel level in the operating menu for en- 11.5.3.12 KID control unit (D795)
gine and transmission.
19 Speed limitation - See Supplier documentation, transmission.

The output shaft speed sensor (B758) D19: Diagnostic menu, see section 8 Control sys-
sends the transmission control unit tem, group 8.4.7.6 TRANSM, menu 6
(D793) pulses with frequency propor-
tional to output shaft rpm.
20 The transmission control unit (D793) Checked by control sys- See section 11 Common electrics, group 11.5.3.9
transmits speed on the CAN bus. tem, error shown with error KIT control unit (D793)
code.
21 The KID control unit (D795) shows the - See section 11 Common electrics, group
machine’s speed. 11.5.3.12 KID control unit (D795)
22 If output shaft rpm is so high that it Checked by control sys- See section 11 Common electrics, group 11.5.3.1
reaches the limit for the machine’s tem, error shown with error Cab control unit (D790-1)
speed limitation, the cab control unit code.
(D790-1) transmits a reduce engine
rpm request on the CAN bus.
23 Control unit engine (D794) restricts - Se Engine control unit, general page 61
engine rpm.

Engine, component locations

page
–

7
4
3 8
2
1 9
10
11
12
13
14
15
16
17
18
010197
19
Volvo TAD760VE, left side (in machine’s direction of travel)
1. Coolant temperature sensor 11. Coolant pump

2. Solenoid valve EGR 12. Sensor oil pressure
3. Crankcase ventilation 13. Oil filter
4. Injector and preheating (6 pcs.) 14. Sensor fuel pressure
5. Turbo 15. Fuel filter
6. Filling point engine oil 16 Solenoid valve proportional valve high-pressure fuel (MPROP)
7. Connection cab heat 17. Electrical connection, engine control unit (D794)
8. Alternator 18. Sensor camshaft rpm
9. Fuel pump 19. Oil plug
10. Sensor fuel pressure (rail)

3
2
010198
1
Volvo TAD760VE, right side (in machine’s direction of travel)
1. Oil plug 4. Sensor crankshaft rpm

2. Starter motor (M654) 5. Thermostat housing
3. Drain point coolant


page
–
(Volvo TAD950VE, TAD952VE and

TAD1250VE engines)
Volvo TAD950VE, TAD952VE and TAD1250VE are straight, 6-cylin-
der, 4-stroke turbocharged low-emission diesel engines with unit injec-
tors and air-to-air intercooler.

Engine heater
˚C
. bar
0 rpm
P I kph
II
III
D5
10 <˚ 1, 5
D10 D1
D7 D11
3,12,7,14,23 11 2,6
D794 D790-1 D790-2
D14
D793 D797-1 D795

20,22 17 15,18,21
D19
D8
D16
D4 D12
H2O
19 M 4
SENSORS
13 16
009686
8 9
The illustration depicts the function description for Volvo TAD950VE,

TAD952VE and TAD1250VE

(D790-1) when the start key is turned tem, group 8.4.1.5 CAN/POWER, menu 5 and
to position 1 or the preheating posi- 8.4.6.4 ENGINE, menu 4
tion.


ignition on via the CAN bus. If the key tem, error shown with error 11.5.3.11 Control unit KIT (D790-2)
is turned to the preheating position, code.
then preheating is also sent on the
CAN bus.
3 If preheating is activated with the start U = 24 V Se Engine control unit, general page 61
key, the engine control unit (D794)
supplies voltage to the preheating re-
lay and thereby the preheating coil.
4 The preheating coil warms the engine - D4: Diagnostic menu, see section 8 Control sys-
intake air. tem, group 8.4.6.5 ENGINE, menu 5

(D790-2) when the start key is turned tem, group 8.4.6.4 ENGINE, menu 4
to start position.
start signal on the CAN bus. 11.5.3.11 Control unit KIT (D790-2)
7 The starter motor (M654) is controlled U = 24 V Starter motor, description (Volvo engine) page 62
by the engine control unit (D794) D7: Diagnostic menu, see section 8 Control sys-
through starter relays and receives tem, group 8.4.6.5 ENGINE, menu 5
signals from the cab control unit
8 The starter motor (M654) cranks the - Starter motor, description (Volvo engine) page 62
engine. D8: Diagnostic menu, see section 8 Control sys-
9 The engine’s sensors send signals to - Se Engine control unit, general page 61
the engine control unit (D794), which
regulates the injectors so that the en-
gine starts.
10 The accelerator pedal (B690) sends U = 0.5–4.5 V See section 11 Common electrics, group 11.5.3.1
the cab control unit (D790-1) a voltage Lower voltage than 0.5 V Cab control unit (D790-1)
signal proportional to the downward and higher voltage than 4.5 D10: Diagnostic menu, see section 8 Control sys-
press of the pedal. V used to detect malfunc- tem, group 8.4.6.1 ENGINE, menu 1
controls.
11 The cab control unit (D790-1) trans- Checked by control sys- See section 11 Common electrics, group 11.5.3.1
mits a message with the rpm request tem, error shown with error Cab control unit (D790-1)
on the CAN bus code. D11: Diagnostic menu, see section 8 Control sys-
12 The engine control unit (D794) in- - Se Engine control unit, general page 61
creases engine speed. D12: Diagnostic menu, see section 8 Control sys-


13 The NO switch for coolant level U = 24 V NO (normally open) switch, coolant level page 60
(B759) sends a voltage signal to the
engine unit (D794) if the coolant level
in the expansion tank is low.
mits engine data and warning mes- tem, error shown with error D14: Diagnostic menu, see section 8 Control sys-
sages on the CAN bus. code. tem, group 8.4.6.6 ENGINE, menu 6, 8.4.6.7 EN-
GINE, menu 7 and 8.4.6.8 ENGINE, menu 8
15 The KID control unit (D795) shows en- - See section 11 Common electrics , group
gine data via display figures. 11.5.3.12 KID control unit (D795)
16 The fuel level sensor (B757) sends U = 0.5–4.5 V Sensor, fuel level, description page 45
the frame control unit (D797-1) a volt- Lower voltage than 0.5 V D16: Diagnostic menu, see section 8 Control sys-
age signal proportional to the fuel lev- and higher voltage than 4.5 tem, group 8.4.3.7 CAB, menu 7
el in the tank. V used to detect malfunc-
controls.
17 The frame control unit (D797-1) trans- Checked by control sys- See section 11 Common electrics, group 11.5.3.2
mits fuel level on the CAN bus. tem, error shown with error Frame control unit (D797-1)
code.
18 The KID control unit (D795) displays - See section 11 Common electrics, group
the fuel level in the operating menu for 11.5.3.12 KID control unit (D795)
engine.
19 The output shaft speed sensor (B758) - See Supplier documentation, transmission.
sends the transmission control unit D19: Diagnostic menu, see section 8 Control sys-
(D793) pulses with frequency propor- tem, group 8.4.7.6 TRANSM, menu 6
tional to output shaft rpm.
20 The transmission control unit (D793) Checked by control sys- See section 11 Common electrics, group 11.5.3.9
transmits speed on the CAN bus. tem, error shown with error KIT control unit (D793)
code.
22 If output shaft rpm is so high that it - See section 11 Common electrics, group 11.5.3.1
reaches the limit for the machine’s Cab control unit (D790-1)
speed limitation, the cab control unit
(D790-1) transmits a reduce engine
rpm request on the CAN bus.
23 Control unit engine (D794) restricts - Se Engine control unit, general page 61
engine rpm.

Engine, component locations (Volvo

page
–
TAD950VE and TAD952VE engines)
7
6
5
4
3
2
1 8
007353
11 10 9
Volvo TAD950VE and TAD952VE engines, left side (in machine’s di-
rection of travel)
1 Connection cab heat 7 Filling coolant
2 Flywheel position sensor and rev sensor 8 Coolant temperature sensor NOTE! Note that the po-
sition differs depending on model.
3 Camshaft position sensor 9 Sensor oil pressure
4 Turbo 10 Oil filter
5 Air preheater with preheating relay 11 Coolant filter
6 Expansion tank

4
5
16
6
15
14
7
8
9
10
11
12
13
007352
Volvo TAD950VE and TAD952VE engines, right side (in machine’s di-
rection of travel)
1 Coolant level sensor (B759) 9 Fuel pre-filter
2 Filling point engine oil 10 Water-in-fuel sensor
3 Charge air pressure and temperature sensor 11 Fuel filter
4 Coolant temperature sensor NOTE! Note that the po- 12 Dipstick

sition differs depending on model.
5 Crankcase pressure sensor 13 Alternator
6 Auxiliary stop 14 Transmission oil cooler
7 Switch for electric feed pump 15 Engine cooler
8 Sensor fuel pressure 16 Intercooler


page
–
(TAD1250VE engine)
2
1
4
7
8
9
10
11
12
13
14
15
16
009637
17
18
Volvo TAD1250VE engine, right side (in machine’s direction of travel)
1. Air preheating downstream of intercooler 10. Water-in-fuel sensor

2. Charge air pressure and temperature sensor 11. Fuel filter
3. Filling point engine oil 12. Engine control unit (D794)
4. Coolant temperature sensor 13. Oil pressure and oil temperature sensor
5. Starter motor (M654) 14. Oil level sensor
6. Rpm sensor 15. Crankcase pressure sensor
7. Sensor fuel pressure 16. Oil plug
8. Fuel pre-filter 17. Dipstick
9. Water separator 18. Alternator

1 3
6
7
009636
8
Volvo TAD1250VE engine, left side (in machine’s direction of travel)
1. Connection cab heat 5. Coolant filter (behind bracket)

2. Thermostat 6. Oil pressure sensor for piston cooling
3. Turbocharger 7. Oil filter (full-flow filter)
4. Coolant pump 8. Oil filter (bypass)

Engine, replacement
page
–
DANGER
The engine is very heavy.
Risk of pinch injury!
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety.
2 Attach hoisting equipment to the engine.
3 Disconnect required hoses and cables before separating engine
and transmission.
NOTE
Drain and collect liquids before detaching hoses.
4 Remove the radiator.
5 Use a jack to secure the gearbox.

6 Remove the screws holding the cover plate to the flywheel.
7 Remove the nuts for the flex plate through the hole under the cov-
er washer.
NOTE
Turn the engine for each nut to be removed from the flex plate.
8 Take up the slack in the hoisting equipment.
NOTE
Do not lift the engine.
9 Remove the screws between engine and gearbox.

10 Remove the screws in the engine brackets.
11 Withdraw the engine rearwards to separate it from the gearbox.
NOTE
Beware of balance before the engine is lifted.
NOTE
If the flex plates are damaged during engine replacement, they
must be replaced.
12 Lift the engine away.

Assembly
13 Apply lubricating grease to the converter connection - both on the
engine and the gearbox.
14 Insert two studs into the flywheel housing as a guide when the en-
gine is installed.
15 Transfer the engine brackets to the new engine; tighten to
169 Nm (oiled screw).
007775
16 Centre a stud on the flywheel so that it aligns with the hole in the
flywheel housing.
007772
17 Lift the engine into place. Make sure that the studs on the fly-
wheel come into correct alignment and do not damage the flex
plate.
18 Install the screws which fix the gearbox and engine, but do not
tighten the screws fully. Leave about a millimetre between the en-
gine and gearbox to facilitate installation of the nuts for the flex
plate/flywheel.
007776

19 Fit the nuts that fix the flex plates at the flywheel in two steps. First
fit the nuts without tightening. Then rotate the flywheel one more
revolution and tighten the nuts to 40 Nm (oiled screw).
NOTE
Turn the engine for each nut to be installed to the flex plate.
20 Tighten the screws which fix the gearbox and engine.
21 Measure and check that the engine is centred in the frame.

22 Fit the screws in the engine bracket.
Tighten to 169 Nm (oiled screw).
23 Fit the cover washer under the flywheel.
24 Install the cooler.
25 Remove the hoisting equipment from the engine.
26 Remove the jack from underneath the gearbox.
27 Connect the required hoses and cables for the engine and trans-
mission. Check and fill fluids as needed.
007973
28 Bleed air from the engine’s fuel system before start.

Engine, replacement (Volvo

page
–
TAD950VE and TAD952VE engines)
DANGER
NOTE
Safety.
and transmission.
NOTE
6 Remove the cover plug.

007761

7 Remove the eight screws in the flex plate through the hole under
the cover plug.
NOTE
Rotate the engine for each bolt in the flex plate that has to be re-
moved.
NOTE
007762
11 Carefully detach the gearbox from the engine.
NOTE
NOTE
must be replaced.

Assembly
15 Insert a stud into one of the nuts on the flexible plate as a guide
when the engine is installed.
007769
Gearbox guide stud

17 Lift the engine into place. Guide the stud through the flywheel and
out through the hole in the flywheel housing.
gine and gearbox to facilitate installation of the screws for the flex
plate/flywheel.
19 Remove the stud through the hole in the flywheel housing.
007770
20 Fit the screws that fix the flex plates at the flywheel in two steps.
First fit the screws without tightening. Then rotate the flywheel
one more revolution and tighten the screws to 40 Nm (oiled
screw).
NOTE
Turn the engine for each screw to be installed in the flex plate.
NOTE
The engine must be loosened from the engine mounts and sep-
arated from the transmission to remove a dropped bolt. Secure
007762
the bolt in the socket when installing.

007895
24 Fit the cover plug in front of the flywheel.
007796


Engine, replacement
page
–
DANGER
NOTE
Safety.
and transmission.
NOTE

6 Remove the cover plugs in front of the flywheel.

Use the outer hole to rotate the engine.
the cover plug.
NOTE
Rotate the engine for each bolt in the flex plate that has to
be removed.
NOTE

10 Remove the screws in the engine brackets and carefully detach
the gearbox from the engine.

Assembly
008301
12 Insert a stud into one of the nuts on the flex plate as a guide when
installing the gearbox.
007769
Gearbox guide stud

14 Lift the engine into place and connect it to the the gearbox, guid-
ing the stud through the flywheel and out through the hole in the
flywheel housing.
15 Fit the screws that fasten the gearbox and engine and tighten
them to 40 Nm (oiled screw).

screw).
NOTE
Turn the engine for each screw to be fitted in the flex plate.
NOTE
The engine must be loosened from the engine mounts and
separated from the transmission to remove a dropped bolt.
Secure the bolt in the socket when installing.
18 Fit the cover plugs in front of the flywheel.



page
–
(Cummins QSB6.7 engine)

Engine heater
˚C
. bar
0 rpm
P I kph
II
III
D5
<˚
1,5
10
D10
D1
D14 D11
3,12,14,23 11,22 2,6
D794 D790-1 D790-2
D7
D793 D797-1 D795
D19 20 17 15,18,21
D16
D12
19 D4 H2O
SENSORS D8
4 13 16
9
009622
8 M 7
The illustration depicts the function description for Cummins QSB6.7

(D790-1) when the start key is tem, group 8.4.1.5 CAN/POWER, menu 5 and
turned to position 1 or the preheating 8.4.6.4 ENGINE, menu 4
position.
ignition on via the CAN bus. If the tem, error shown with er- 11.5.3.1 KIT control unit (D790-2)
key is turned to the preheating posi- ror code.
tion, then preheating is also sent on
the CAN bus.


3 If preheating has been activated with U = 24 V Se Engine control unit, general page 61
the start key or automatically, then
the engine control unit (D794) feeds
voltage to the preheating relay and
through this also the preheating coil
(E800).
4 The preheating coil (E800) heats the - D4: Diagnostic menu, see section 8 Control sys-
primary air to the engine. tem, group 8.4.6.5 ENGINE, menu 5

(D790-2) when the start key is tem, group 8.4.6.4 ENGINE, menu 4
turned to start position.
start signal on the CAN bus. 11.5.3.1 KIT control unit (D790-2)
7 The starter motor (M654) is control- U = 24 V Starter motor, description (Cummins engine)
led by the engine control unit (D797- page 62
1) via a starter relay and receives D7: Diagnostic menu, see section 8 Control sys-
signals from the cab control unit tem, group 8.4.6.5 ENGINE, menu 5
8 The starter motor (M654) cranks the - Starter motor, description (Cummins engine)
engine. page 62
D8: Diagnostic menu, see section 8 Control sys-
9 The engine’s sensors send signals - Engine control unit, general page 61
to the engine control unit (D794),
which regulates the injectors so that
the engine starts.
10 The accelerator pedal (B690) sends U = 0.2–4.8 V Section 9 Frame, body, cab and accessories,
the KCU cab control unit (D790-1) a Lower voltage than 0.2 V group 9.1 Controls and instruments
voltage signal proportional to the and higher voltage than D10: Diagnostic menu, see section 8 Control
downward press of the pedal. 4.8 V is used to detect system, group 8.4.6.1 ENGINE, menu 1
malfunction in cable har-
nesses and controls.
11 The KCU cab control unit (D790-1) Checked by control sys- See section 11 Common electrics, group
sends the engine control unit (D794) tem, error shown with er- 11.5.3.1 Cab control unit (D790-1)
an rpm request via the CAN bus. ror code. D11: Diagnostic menu, see section 8 Control
system, group 8.4.6.1 ENGINE, menu 1
12 The engine control unit (D794) in- - Engine control unit, general page 61
creases engine speed. D12: Diagnostic menu, see section 8 Control
13 The NO switch for coolant level U = 24 V NO (normally open) switch, coolant level page
(B759) sends a voltage signal to the 60
engine unit (D794) if the coolant lev-
el in the expansion tank is low.


mits engine data and warning mes- tem, error shown with er- D14: Diagnostic menu, see section 8 Control
sages on the CAN bus. ror code. system, group 8.4.6.6 ENGINE, menu 6, 8.4.6.7
ENGINE, menu 7 and 8.4.6.8 ENGINE, menu 8
engine data via display figures. 11.5.3.12 KID control unit (D795)
16 The fuel level sensor (B757) sends R = 4–73 ohm Sensor, fuel level, description page 45
the frame control unit (D797-1) a A warning message ap- D16: Diagnostic menu, see section 8 Control
voltage signal proportional to the fuel pears on the display if the system, group 8.4.3.7 CAB, menu 7
level in the tank. amount of fuel in the tank
is less than 15% for more
than 40 seconds.
17 The frame control unit (D797-1) Checked by control sys- See section 11 Common electrics, group
transmits fuel level on the CAN bus. tem, error shown with er- 11.5.3.2 Frame control unit (D797-1)
ror code.
fuel level in the operating menu for 11.5.3.12 KID control unit (D795)
engine and transmission.
19 Speed limitation - See Supplier documentation, transmission.

The output shaft speed sensor D19: Diagnostic menu, see section 8 Control
(B758) sends the transmission con- system, group 8.4.7.6 TRANSM, menu 6
trol unit (D793) pulses with frequen-
cy proportional to output shaft rpm.
20 The transmission control unit (D793) Checked by control sys- See section 11 Common electrics, group
transmits speed on the CAN bus. tem, error shown with er- 11.5.3.9 KIT control unit (D793)
ror code.
the machine’s speed. 11.5.3.12 KID control unit (D795)
22 If output shaft rpm is so high that it Checked by control sys- See section 11 Common electrics, group
reaches the limit for the machine’s tem, error shown with er- 11.5.3.1 Cab control unit (D790-1)
speed limitation, the KCU cab con- ror code.
trol unit (D790-1) transmits a reduce
engine rpm request on the CAN bus.
23 Control unit engine (D794) restricts - Engine control unit, general page 61
engine rpm.


page
–
(Cummins QSB6.7 engine)
3
2
1
9
10
11
12
13
14
009619
15
Cummins QSB6.7 engine, left side (in machine’s direction of travel)
1 Crankcase ventilation 9 Oil cooler

2 Injector drainage 10 Oil filter
3 Lifting eye 11 Turbo
4 Oil filling 12 Turbo wastegate
5 Coolant outlet 13 Exhaust manifold
6 Alternator 14 Starter motor (M654)
7 Drive belt tensioner 15 Flywheel housing
8 Coolant inlet

3 4
5
6
2
1 7
9
10
11
12
13
009621
Cummins QSB6.7 engine, right side (in machine’s direction of travel)
1 Air intake with preheating 8 Pressure reducing valve in rail

2 Coolant temperature sensor 9 Fuel filter
3 Turbo air inlet 10 Dipstick
4 Turbo air outlet 11 Oil filling
5 High-pressure fuel lines 12 Electronic control unit
6 Fuel pressure sensor in rail 13 Fan
7 Fuel rail


page
–
(Cummins QSM11 engine)

Engine heater
˚C
. bar
0 rpm
P I kph
II
III
D3
<˚ 1,3
8
D8 D1
12,21 2,9 4,13

D794 D790-1 D790-2
D793 D797-1 D795

18,20 5,10,15 16,19
D17 D12
D5 D14
SENSORS H2O M
009644
17 7 11 6 14
The illustration depicts the function description for Cummins QSM11

1 The ignition switch (S150) sends a volt- U = 24 V Ignition switch function page 43
age signal to the KCU cab control unit D1: Diagnostic menu, see section 8 Control
(D790-1) when the start key is turned to system, group 8.4.1.5 CAN/POWER, menu
position 1. 5 and 8.4.6.4 ENGINE, menu 4
2 The KCU cab control unit (D790-1) trans- Checked by control sys- See section 11 Common electrics, group
mits "ignition on" on the CAN bus. tem, error shown with er- 11.5.3.1 Cab control unit (D790-1)
ror code.
3 The ignition switch (S150) sends a volt- U = 24 V Ignition switch function page 43
age signal to the KIT control unit (D790-2) D3: Diagnostic menu, see section 8 Control
when the start key is turned to start posi- system, group 8.4.6.4 ENGINE, menu 4
tion.
4 Control unit KIT (D790-2) transmits a start Checked by control sys- See section 11 Common electrics, group
signal on the CAN bus. tem, error shown with er- 11.5.3.11 Cab control unit (D790-2)
ror code.


5 The frame control unit (D797-1) transmits U = 24 V Starter motor, description (Cummins en-
voltage to the starter motor (M654). gine) page 62
D5: Diagnostic menu, see section 8 Control
6 The starter motor (M654) cranks the en- - Starter motor, description (Cummins en-
gine. gine) page 62
7 The engine’s sensors send signals to the - Se Engine control unit, general page 61
engine control unit (D794), which regu-
lates the injectors so that the engine
starts.
8 The accelerator pedal (B690) sends the U = 0.2–4.8 V Section 9 Frame, body, cab and accesso-
KCU cab control unit (D790-1) a voltage Lower voltage than 0.2 V ries, group 9.1 Controls and instruments
signal proportional to the downward press and higher voltage than D8: Diagnostic menu, see section 8 Control
of the pedal. 4.8 V is used to detect system, group 8.4.6.1 ENGINE, menu 1
malfunction in cable har-
nesses and controls.
9 The KCU cab control unit (D790-1) sends Checked by control sys- See section 11 Common electrics, group
the engine control unit (D794) an rpm re- tem, error shown with er- 11.5.3.1 Cab control unit (D790-1)
quest via the CAN bus. ror code.
10 The engine control unit (D794) increases - Se Engine control unit, general page 61
engine speed.
11 The NO switch for coolant level (B759) U = 24 V Cooling system, description page 49
sends a voltage signal to the engine unit
(D794) if the coolant level in the expan-
sion tank is low.
12 The engine control unit (D794) transmits Checked by control sys- Se Engine control unit, general page 61
engine data and warning messages on tem, error shown with er- D12: Diagnostic menu, see section 8 Con-
the CAN bus. ror code. trol system , group 8.4.6.6 ENGINE, menu
6 and 8.4.6.7 ENGINE, menu 7
13 The KID control unit (D795) shows engine - See section 11 Common electrics , group
data via display figures. 11.5.3.12 KID control unit (D795)
14 The fuel level sensor (B757) sends the R = 4–73 ohm Sensor, fuel level, description page 45
frame control unit (D797-1) a voltage sig- D14: Diagnostic menu, see section 8 Con-
nal proportional to the fuel level in the trol system, group 8.4.3.7 CAB, menu 7
tank. A warning message appears on the
display if the amount of fuel in the tank is
less than 15% for more than 40 seconds.
15 The frame control unit (D797-1) transmits Checked by control sys- See section 11 Common electrics, group
fuel level on the CAN bus. tem, error shown with er- 11.5.3.2 Frame control unit (D797-1)
ror code.
16 The KID control unit (D795) displays the - See section 11 Common electrics , group
fuel level in the operating menu for en- 11.5.3.12 KID control unit (D795)
gine.


17 Speed limitation - D17: Diagnostic menu, see section 8 Con-
The output shaft speed sensor (B758) trol system , group 8.4.7.6 TRANSM, menu
sends the transmission control unit 6
(D793) pulses with frequency proportional
to output shaft rpm.
18 The transmission control unit (D793) Checked by control sys- See section 11 Common electrics, group
transmits speed on the CAN bus. tem, error shown with er- 11.5.3.9 KIT control unit (D793)
ror code.
20 If output shaft rpm is so high that it reach- Checked by control sys- See section 11 Common electrics, group
es the limit for the machine’s speed limita- tem, error shown with er- 11.5.3.1 Cab control unit (D790-1)
tion, the KCU cab control unit (D790-1) ror code.
transmits a reduce engine rpm request on
the CAN bus.
21 Control unit engine (D794) restricts en- - Se Engine control unit, general page 61
gine rpm.


page
–
(Cummins QSM11 engine)

1 2 3 4 5 6 7 8 9 10 11 12
20
19
18
004463
17 16 15 14 13
Cummins QSM11 engine, left side (in machine’s direction of travel)
1 Engine oil filling point 11 Expansion tank connection

2 Dipstick 12 Radiator connection (outlet)
3 Air cleaner connection 13 Coolant pump
4 Turbocharger 14 Thermostat housing
5 Intercooler connection (outlet) 15 Radiator connection (intake)
6 Intercooler connection (intake) 16 Expansion tank connection
7 Intake temperature sensor 17 Oil filter
8 Exhaust system connection 18 Coolant filter
9 Boost pressure sensor 19 Coolant shut-off cock
10 Alternator (coolant temperature sensor behind alternator) 20 Connection cab heat

1 2 3 4
009728
13 12 11 10 9 8 7 6 5
Cummins QSM11 engine, right side (in machine’s direction of travel)
1 Vibration damper 8 Draining of condensation from fuel filter and water-in-fuel sensor
2 Location for air conditioning compressor 9 Fuel filter
3 Fuel connection (outlet) 10 Sensor fuel pressure
4 Engine control unit (D794) 11 Fuel pump
5 Engine oil drain plug 12 Oil pressure and oil temperature sensor
6 Starter motor (M654) 13 Crankshaft position sensor
7 Fuel connection (intake)

Engine, replacement
page
–
(Cummins engine)
DANGER
NOTE
Safety.
and transmission.
NOTE
009088
6 Remove the screws holding the cover plate to the flywheel on the
left side of the engine.
008314

7 Remove the screws in the flex plate through the hole under the
cover plug.
NOTE
Rotate the engine for each bolt in the flex plate that has to be re-
moved.
NOTE
008315

11 Carefully detach the gearbox from the engine.
NOTE
008275
NOTE
must be replaced.
Assembly
008301

16 Insert a stud into one of the nuts on the flexible plate as a guide
when the engine is installed.
007769
Gearbox guide stud

17 Lift the engine into place. Guide the stud through the flywheel and
out through the hole in the flywheel housing.
plate/flywheel.
008319
screw).
NOTE
Turn the engine for each screw to be installed in the flex plate.
NOTE
008315
008275


24 Fit the cover plug in front of the flywheel.
007796

1 Engine – 1.1 Controls and instruments 43
1.1 Controls and instruments

1.1.1 Ignition switch
Ignition switch function
page
–
P No function.
0 Stop position. Ignition cut off, i.e. everything off.
Key can be removed.
I Operating position.
Voltage to all electrical functions. Engine and transmis-
sion control units are now active.
The signal can be checked via the diagnostic menu. See
section 8 Control system, group 8.4.1.5 CAN/POWER,
menu 5 and 8.4.6.4 ENGINE, menu 4.
II For Volvo TAD760VE, TAD950VE, TAD952VE,
TAD1250VE and Cummins QSB6.7 engines: Preheating
position.
0 For QMS11 engine: No function
P When the switch is in the preheating position, the engine’s

I
intake air is manually heated to a suitable temperature
with glow plugs in each cylinder on Volvo engines (Cum-
mins engines are heated automatically with a heating
II coil). The preheating lamp is on during the preheating
process.
The signal can be checked from the diagnostic menu, see
003689
III section 8 Control system, group 8.4.6.4 ENGINE,

menu 4.
III Start position.
Engagement of starter motor for engine start.
NOTE
The machine is equipped with an electric restart in-
terlock, which prevents engagement of the starter
motor when the engine is rotating.
Conditions for starter motor engagement are that the
transmission is in neutral position and the engine is
not already running.
The signal can be checked from the diagnostic menu, see
section 8 Control system, group 8.4.6.4 ENGINE,
menu 4.

44 1 Engine – 1.1.2 Accelerator pedal
1.1.2 Accelerator pedal

Accelerator pedal, replacement
page
–

2 Pull one edge of the cover away to facilitate access to the accel-
erator pedal.
3 Unplug the cable from the connector.
4 Unscrew the connector from the accelerator pedal.
5 Replace the accelerator pedal.
6 Fit in the reverse order.
7 Calibrate the accelerator pedal. See section 8 Control system.
1. Accelerator pedal
2. Brake pedal
Accelerator pedal, calibration

page
–
See section 8 Control system, group 8.5.2.3 Calibrate DRIVE-TRAIN.

1 Engine – 1.2 Fuel system 45
1.2 Fuel system

Fuel system, description
page
–
The fuel system distributes fuel between the cylinders and thereby
controls the engine output power and rpm.
When the engine is started, the fuel pump sucks fuel from the tank
through the fuel filter and forces it to the unit injections. The unit injec-
tors spray in the fuel and atomises the fuel to the engine’s combustion
chamber.
See Engine, component locations (Volvo TAD760VE engine) page 8,
Engine, component locations (Volvo TAD950VE and TAD952VE en-
gines) page 13, Engine, component locations (TAD1250VE engine)
page 15, Engine, component locations (Cummins QSB6.7 engine)
page 32 or Engine, component locations (Cummins QSM11 engine)
page 37 for component locations.
WARNING
Fuel under high pressure.
Risk of personal injury.
Fuel pressure is so high that a jet can injure the skin

resulting in serious injuries. Use protective gloves
and safety glasses. Hold a rag above the connection
to collect the fuel.
1.2.1 Fuel tank

Fuel tank, description
page
–
The fuel tank is located on the left-hand side of the machine behind the
brake fluid reservoir.
007113
1 2 3
1. Fuel filler
2. Fuel tank
3. Fuel level sensor
1.2.2 Sensor, fuel level

Sensor, fuel level, description
page
–
The signal can be checked from the diagnostic menu, see section 8
Control system, group 8.4.3.7 CAB, menu 7

46 1 Engine – 1.6 Air intake and exhaust outlet
1.6 Air intake and exhaust outlet

1.6.1 Air cleaning system
Air cleaning system, description
page
–
The air cleaning system consists of an air cleaner with filter, filter indi-
cator, pipes and hoses. There are two filters in the air cleaner that
clean the air and a dust reservoir that collects larger particles. The dust
reservoir can be emptied without opening the air cleaner.
Combustion in the engine requires air. Free unobstructed flow for
fresh air and exhausts is essential for effective engine operation.
When the air filter cleans the air for engine, particles collect in the filter
material. With time, so many particles collect that the filter does not let
through enough air for effective combustion, then the filter has to be
replaced. The filter indication measures the vacuum pressure on the
engine side of the filter. When the filter is clogged, the vacuum pres-
sure increases and the indicator indicates that it’s time to replace filter.
004468
1 2 3 4 5 As an option, the machine can be equipped with a high-position air in-

1. Dust reservoir let with pre-cleaner. It consist of an extension of the inlet pipe to the air
filter and a pre-cleaner that filters coarser particles by creating cy-
2. Air cleaner
clones at the air inlet. The pre-cleaner does not have any parts that
3. Intake need to be replaced. When operating in dirty conditions, this means
4. Filter indicator that less dusty air is drawn into the air cleaner, extending the service
life of the air filters.
5. Induction pipe

1 Engine – 1.6.3 Exhaust system 47
1.6.3 Exhaust system

Exhaust system, description
page
–
The exhaust system is installed in the chassis. A heat shield is in-

stalled between the engine and the exhaust system to protect wiring,
1 etc. A flex pipe between the turbo and muffler absorbs the engine’s
movements. On the outside of the machine, there is a heat shield over
the exhaust system.
WARNING
2
Hot exhaust system!
Risk of burn injuries!

9 Never touch the turbo or muffler when the machine is
8 3 running or just after it has been turned off!
4
7
004461
6 5
Exhaust system overview
1. Tail pipe
2. Cab undercarriage bracket
3. Frame bracket
4. Silencer
5. Brackets for suspending exhaust pipe and
silencer
6. Exhaust pipe
7. Heat shield mounted on exhaust pipe
8. Flex pipe
9. Connection to turbocharger

48 1 Engine – 1.6.4 Intercooler
1.6.4 Intercooler
Intercooler, description
page
–
The charge-air is cooled by an air-air intercooler in the upper part of

the cooler unit.
Also refer to Cooling system, description page 49.
1
3
003215
Radiator assembly
1. Intercooler
2. Engine radiator
3. Transmission oil cooler
4. Transmission oil thermostat
5. Condenser mounting (to AC)

1 Engine – 1.7 Cooling system 49
1.7 Cooling system

Cooling system, description
page
–
The engine is water-cooled and has passages through which the cool-
ant from the radiator flows round a closed system.
Main parts of the cooling system:
• Coolant pump, located in the engine.
• Expansion tank, located in the engine compartment.
• Thermostat, located in the engine
• Cooling fan, located in front of the radiator
• Water cooler, part of radiator assembly (middle).
• Engine oil cooler, located in the engine
• Transmission oil cooler, part of radiator assembly (lower).
• Intercooler, part of radiator assembly (upper).
• Fuel cooler, located behind the radiator
• Coolant filter, located in engine (for Volvo TAD950VE,
TAD952VE, TAD1250VE and Cummins QSM11 engines).
How the engine cooling system works:
1. Coolant is circulated through the cylinder head, engine block and
oil cooler by the coolant pump.
2. The thermostat directs the heated coolant back to the coolant
pump or through the radiator.
3. When the coolant is colder than the thermostat opening tempera-
ture it is pumped back to the engine.
When the coolant is warmer than the thermostat opening temper-
ature it is pumped through the radiator and then back to the cool-
ant pump.
4. The expansion tank allows the coolant to expand without escap-
ing from the engine.

50 1 Engine – 1.7.4 Radiator and expansion tank
1.7.4 Radiator and expansion tank

Radiator and expansion tank, description
page
–
The radiator for the engine is located in the radiator assembly (made
of aluminium) which is located behind the engine.
The purpose of the cooler assembly is to cool:
1 • Engine coolant.
• Transmission oil (cooled in the lower part of the radiator assem-
bly), see also section 2 Transmission, group 2.6.3 Oil cooler.
• Charge air (cooled in the upper part of the radiator assembly), see
also Intercooler, description page 48.
Also refer to Cooling system, description page 49.
For more information, see supplier documentation, engine.
3
003215
Radiator assembly
1. Intercooler
2. Engine radiator

1 Engine – 1.7.5 Cooling fan 51
1.7.5 Cooling fan

Drive belt/alternator belt, replacement
page
–
Drive belt, changing (engine alternative Volvo TAD760VE)

1. Machine in service position, see section B Safety.
2. Loosen the belt tensioner and lock it with a drift (1).
1
007314
Volvo TAD760VE
3. Remove the belt from the coolant pump first.
4. Install the new belt.
Undo the belt tensioner and check that the belt is correctly posi-
tioned in the groove and is correctly tensioned.
1
007969
Volvo TAD760VE

52 1 Engine – 1.7.5 Cooling fan
Drive belt, replacement (Volvo TAD950VE and TAD952VE

engines)
2. Remove the protective mesh and the outer fan ring around the
cooling fan.
3. remove the protective plates from around the drive belts.
4. Fit a 1/2" spanner in the belt tensioner (position 1). Lift up the
spanner and remove the drive belt.
5. Guide the drive belt around the fan blade and remove it.
6. Check that the belt pulleys are clean and undamaged.
007532 7. Guide the new drive belt over the fan.

8. Lift up the 1/2" spanner and fit the new drive belt.
1 9. Fit the protective plates around the drive belts.
Volvo TAD950VE and TAD952VE 10. Fit the protective mesh and the outer fan ring around the cooling
fan.
11. Start the engine and perform a functionality check.
Alternator belt, replacement (Volvo TAD950VE and

TAD952VE engines)
2. Remove the protective mesh and the outer fan ring around the
cooling fan.
3. remove the protective plates from around the drive belts.
4. Fit a 1/2" spanner in the belt tensioner (position 1). Lift up the
spanner and lift off the drive belt for the water pump.
2
5. Fit a 1/2" spanner in the belt tensioner (position 2). Press down
the spanner and remove the alternator belt.
6. Check that the belt pulleys are clean and undamaged.
7. Press down the 1/2" spanner of the belt tensioner (position 2) a fit
007315
1 the new alternator belt.

8. Lift up the 1/2" spanner of the belt tensioner (position 1) and refit
Volvo TAD950VE and TAD952VE the drive belt of the water pump.
9. Fit the protective plates around the drive belts.
10. Fit the protective mesh and the outer fan ring around the cooling
fan.
11. Start the engine and perform a functionality check.

1 Engine – 1.7.5 Cooling fan 53
Drive belt, changing (engine alternative Volvo TAD1250VE)

2 Remove the protective plates from around the engine and radia-
tor.
3 Relieve the tension on the belt tensioner and remove the drive
belt from the belt tensioner pulley.
4 Remove the drive belt.
5 Fit the new drive belt as illustrated.
The figure shows the engine without the cooling fan

54 1 Engine – 1.7.5 Cooling fan
Drive belt, replacement (Cummins QSB6.7 engine)

2. Lift up the belt tensioner to remove the drive belt.
NOTE
The belt tensioner tensions in the same direction as the
spring is bent over the belt tensioner arm. To reduce tension
in the belt, rotate the belt tensioner to tighten the spring.
CAUTION
008013
Do not use too much force in or against the tension-
ing direction after the belt tensioner has been ten-
sioned to its positive stop. This could break the belt
tensioner.
3. Lift up the belt tensioner and fit the drive belt. If it is difficult to fit
(the belt seems too short), first position the belt on the grooved
pulley. Then continue holding up the belt tensioner and wriggle
the belt over the water pump pulley.
Undo the belt tensioner and check that the belt is correctly posi-
tioned in the groove and is correctly tensioned.
Drive belt, replacement (Cummins QSM11 engine)

2 Remove the protective plates from around the engine and radia-
tor.
3 Remove the belt tensioner.
4 Remove the drive belt.
5 Install the new drive belt.
6 Use the belt tensioner to tension the drive belt.

1 Engine – 1.7.7 Coolant 55
1.7.7 Coolant
Changing coolant and cleaning the cooling system
page
–
(Volvo engine)
Cooling performance is reduced due to deposits in the radiator and
cooling channels. Always clean the cooling system in connection with
coolant change.
IMPORTANT
Cleaning may not be performed if there is a risk of
freezing in the cooling system since the cleaning so-
lution does not have anti-freeze properties.
NOTE
Read the safety instructions before starting work with the cooling
system, see section B Safety.
NOTE
Before draining, stop the engine and remove the filler cap.
Draining
1 Remove the filler cap from the cooling system’s expansion tank.
2 Open all drain points. Drain the coolant from the radiator and en-
gine block with the drain hose. The drain nipples are located un-
der the radiator and on the engine block’s right side.
3 Check that all coolant drains.
NOTE
There may be deposits inside the tap or the plug. These
must be cleaned away, otherwise there is a risk that coolant
may remain and cause freezing damage.
Check if the installation has additional valves or plugs at the cool-
007394
ant lines’ lowest points. Let drain valves or plugs be open and
make sure that the heat control is at max. heat when cleaning.
Drain point, engine.
4 Insert a hose in the filler hole in the expansion tank and flush with
clean water, until the draining water is clear.
5 If impurities remain after flushing for a long time, it’s possible to
clean with coolant. Otherwise, continue with step 10.
Cleaning with coolant

6 Fill the cooling system with 15-20 % concentrated coolant mix-
ture. Only use recommended concentrated coolant mixed with
clean water.
7 Drain the cooling system after 1-2 days of operation.

56 1 Engine – 1.7.7 Coolant
NOTE
To prevent dissolved material from clogging the system
again, drain the system quickly, within 10 minutes, without
the machine’s engine being off for a long time. Remove the
filler cap from the expansion tank and also the lower coolant
hose to increase drain speed.
8 Flush the system immediately and very thoroughly with clean
warm water to prevent impurities from settling again on the inner
surfaces. Flush until the draining water is completely clean. Make
sure that the heat control is at max. heat when cleaning.
9 If impurities should remain after flushing for a long time, then
cleaning can be performed with a radiator cleaning agent and an
aftertreatment with a neutralizing agent.
NOTE
Only use cleaning agents approved by the engine manufac-
turer. Carefully follow the instructions on the package.
Filler orifice
10 When the cooling system is completely free from impurities, close
the drain valves.
NOTE
Only use recommended coolant.
IMPORTANT
It is very important that the correct concentration and
volume of coolant is filled in the system. Mix in a sep-
arate clean container for filling the cooling system, be
sure that the fluids mix.
11 Fill coolant so that the level ends up between MIN and MAX
markings. See Coolant, mixing page 59. The engine must not
be started until the system is bled and completely filled.
12 Start the engine when the engine is completely bled free from air
and filled with coolant. Open any breather valves for a time after
start, so that any trapped air can escape.
Open all heat controls on the heater so that it is bled free from air.
13 Stop the engine after approx. one hour and check the coolant lev-
el, top up if needed.

Changing coolant and cleaning the cooling system

page
–
(Cummins engine)
Because cooling performance is reduced by deposits in the radiator
and cooling channels, clean the cooling system when changing cool-
ant.
IMPORTANT
Cleaning may not be performed if there is a risk of
freezing in the cooling system since the cleaning so-
lution does not have anti-freeze properties.
NOTE
Read the safety instructions for coolant before starting work, see
section B Safety.
NOTE
Before draining, stop the engine and remove the filler cap.
1 Remove the filler cap from the cooling system’s expansion tank.
2 Open all drain points. Drain the coolant from the radiator and en-
gine block. There is a drain nipple under the radiator and a drain
plug under the coolant inlet on the engine block.
3 Check that all coolant drains.
NOTE
There may be deposits inside the tap or the plug. These
must be cleaned away, otherwise there is a risk that coolant
may remain and cause freezing damage.
Check if the installation has additional valves or plugs at the low-
008020
est points of the coolant lines. Leave drain valves or plugs open
and make sure that the heat control is at max. heat when clean-
ing.
4 Check the condition of the hoses and clamps and check the radi-
ator for leaks. Replace and clean as necessary.
CAUTION
The system must be filled well to prevent air pocket
formation. During filling, air must be vented out from
the cooling channels. Wait 2 to 3 minutes to vent the
system and then fill it.

58 1 Engine – 1.7.7 Coolant
5 Cleaning:
NOTE
Do not fit the pressure cap. The engine must be run without
pressure cap during this process.
Fill the system with a mixture of sodium carbonate and water (or
similar).
NOTE
008021
Use 0.5 kg sodium carbonate per 23 litres of water.
6 Start and run the engine for 5 minutes with coolant temperature
over 80 °C.
Switch off the engine and drain the cooling system.
7 Fill the cooling system with clean water.
NOTE
Make sure that the system is properly bled during filling.
NOTE
Do not fit the cap.
008022
8 Start and run the engine for 5 minutes with coolant temperature
over 80 °C.
Switch off the engine and drain the cooling system.
NOTE
If the water that drains out is still dirty, the system must be
flushed until the water is clean.
9 When the cooling system is completely free from impurities, close
the drain valves and plugs.
NOTE
Only use recommended coolant.
NOTE
Never use pure water as a coolant. This could cause corrosion
damage to the cooling system.
IMPORTANT
arate clean container prior to filling the cooling sys-
tem. Be sure that the fluids mix well.

10 Filling:
Fill coolant so that the level ends up between MIN and MAX
markings. The engine must not be started until the system is
bled and completely filled.
11 Fit the pressure cap and start the engine once the cooling system
has been completely bled and filled.
Open all heat controls on the heater so that it is bled free from air.
12 Stop the engine after approx. one hour and check the coolant lev-
el, top up if needed.
Coolant, mixing
page
–
NOTE
Read the safety instructions for coolant before starting work, see
section B Safety.
IMPORTANT
Ethylene glycol shall not be mixed with other types of
glycol.
Mix
40% glycol
60% water
This mixture protects against internal corrosion, cavitation and freez-
ing down to -28 °C (At 60% glycol mixture, the freezing point is lowered
to -54 °C.) Never mix more than 60% concentrated glycol in the cool-
ant as this reduces cooling effect with risk of overheating and reduces
frost protection.
IMPORTANT
Mix the coolant with clean water.
007395
IMPORTANT
arate, clean container before filling the cooling sys-
tem. Make sure that the fluids mix.

60 1 Engine – 1.7.8 NO (normally open) switch, coolant level
IMPORTANT
On machines with ECC or AC, it is vital that the engine
cooling system is refilled with coolant with the right
concentration of anti-freeze. Otherwise there is a risk
that the air conditioning heating coils will freeze when
the cooling function is used during period when the
heating is completely switched off.
NOTE
It is important that the coolant is mixed correctly all year to ensure
adequate corrosion protection. The corrosion-protective proper-
ties decline with time, that is why the coolant has to be changed
according to given intervals.
1.7.8 NO (normally open) switch, coolant

level
NO (normally open) switch, coolant level, description
page
–
The coolant level NO switch is located on the expansion tank.
1.7.10 Engine heater

Engine heater, description
page
–
See supplier documentation, engine.

A start-inhibitor function is available as an option coupled with the en-
gine heater. The function is activated when the heater is running.

1 Engine – 1.9 Control system engine 61
1.9 Control system engine

1.9.1 Control unit, engine
Engine control unit, general
page
–
See section 11 Common electrics, group 11.5.3.10 Engine control unit

and supplier documentation, engine.

62 1 Engine – 1.11 Start/stop
1.11 Start/stop
1.11.1 Starter motor
Starter motor, description (Volvo engine)
page
–
In order to save output when the engine is started, the attachment

pump is disconnected. The pump is reconnected when the engine has
started and reached idling speed.
The starter motor cranks the engine until fuel combustion begins and
the engine starts.
The starter motor is supplied with voltage directly from the start batter-
ies. A relay on the starter motor (solenoid) is activated by the engine
control unit (D794).
Control system, group 8.4.6.5 ENGINE, menu 5.
Starter motor, description (Cummins engine)

page
–
The starter motor cranks the engine until fuel combustion begins and
the engine starts.
The starter motor is supplied with voltage directly from the start batter-
ies. A relay on the starter motor (solenoid) is activated by the frame
control unit (D797-1).
Control system, group 8.4.6.5 ENGINE, menu 5.
1.11.2 Stopping device

Stopping device, description
page
–
The engines have electrically regulated injectors that stop delivering

fuel when the voltage is cut off, which means that the engine stops.
The engine can only be stopped by turning off the ignition via the igni-
tion switch.
NOTE
The battery disconnect switch must not be used for emergency
stop!
Start lock-out is available as an option, where a code has to be

entered via the display before the engine can be started.
Automatic engine shutdown is available as an option. This means

that the engine shuts off automatically after 3-10 minutes (depending
on customer setting) if the machine is idling without the operator in the
seat.

2 Transmission 1
2 Transmission
Table of Contents 2 Transmission

mm mm mm mm mm mm
2 Transmission.................................................................................................. 3
2.1 Controls and instruments ......................................................................... 39
2.1.1 Gear selector and multi-function lever ................................................. 39
2.2 Torque converter/Clutch system .............................................................. 40
2.2.1 Flex plates ........................................................................................... 40
2.6 Lubrication system ................................................................................... 42
2.6.3 Oil cooler .............................................................................................. 47
2.7 Cooling system ......................................................................................... 49
2.7.3 Oil cooler .............................................................................................. 49
2.8 Transmission control system .................................................................... 50
2.8.1 Control unit transmission ..................................................................... 50
2.8.2 Normally closed (NC) switch, disengagement ..................................... 50
2.8.3 Transmission cable harness ................................................................ 51

2 2 Transmission

2 Transmission – 2 Transmission 3
2 Transmission
mm mm mm mm mm mm
Transmission, general
page
–
The transmission is fully automatic with a torque converter. TE17312

has 3 forward gears and 3 reverse gears while TE32418 has 4 forward
gears and 4 reverse gears.
DCF 280-330 is equipped with Dana TE17312 and can be used with
the following engine alternatives:
• Cummins QSB6.7
• Volvo TAD760VE
DCF 330 can also use the following engine alternatives:
• Volvo TAD950VE
DCF 370-500 is equipped with Dana TE32418 and can be used with
the following engine alternatives:
• Volvo TAD952VE
• Volvo TAD1250VE
• Cummins QSM11

The workshop manual only describes components and work descrip-
tions that concern installation in the machine. For descriptions of and
instructions for transmission components and systems, refer to the
supplier documentation.
References to component supplier documentation are only provided in
exceptional cases. If information about a component is not found, the
component supplier documentation should be used.

4 2 Transmission – 2 Transmission
Transmission, function description

page
–
(TE17312)
Sensor operator in Operator in seat Section 9 Frame, body, cab and accessories, group 9.3.14 Operator-in-seat
seat sensor
F
R
<˚ 1
22 5 D1
D5
21 6, 23 2, 7
D794 D790-1 D790-2
D793 D795 D797-1

10, 16, 18, 20, 26 19 25
D13
D8 D14
D9 D15 D22
9 D20
D12 ˚C D24 Pa
8 12 13 14 15
Pa ˚C 24
4 17
11
3
009696
The illustration depicts the function description for TE17312

1 The gear selector sends a voltage sig- Forward, Conn. F: U = 24 V See section 9 Frame, body, cab and accessories,
nal to the KIT control unit (D790-2). Reverse, Conn. R: U = 24 V group 9.1 Controls and instruments.
tem, group 8.4.7.2 TRANSM, menu 2
2 The KIT control unit (D790-2) trans- Checked by control sys- See section 11 Common electrics , group
mits the selected direction of travel tem, error shown with error 11.5.3.11 Control unit KIT (D790-2)
(forward or reverse) on the CAN bus. code.
3 The transmission’s oil pump pumps oil - -

when the engine is running.


4 The transmission’s oil filter cleans the - -
oil from impurities.
5 The accelerator pedal transmits a sig- U = 0.5-4.5 V See section 1 Engine, group 1.1.2 Accelerator
nal to the cab control unit (D790-1). pedal
tem , group 8.4.6.1 ENGINE, menu 1
6 The cab control unit (D790-1) trans- Checked by control sys- See section 11 Common electrics , group
mits the desired throttle application on tem, error shown with error 11.5.3.1 Cab control unit (D790-1)
the CAN bus. code.
7 The KIT control unit (D790-2) trans- Checked by control sys- See section 11 Common electrics , group
mits the selected shifting program on tem, error shown with error 11.5.3.11 Control unit KIT (D790-2)
the CAN bus. code.
8 The oil pressure sensors sends a volt- Checked by Control unit D8: Diagnostic menu, see section 8 Control sys-
age signal to the transmission control transmission, error shown tem , group 8.4.7.10 TRANSM, menu 10
unit (D793) if oil pressure is too low. with error code.
9 The engine speed and oil temperature Checked by Control unit D9: Diagnostic menu, See Section 8 Control sys-
sensor (B758/766) sends the trans- transmission, error shown tem , group 8.4.7.6 TRANSM, menu 6 and
mission control unit (D793) a pulse with error code. 8.4.7.10 TRANSM, menu 10
signal with frequency proportional to
engine speed and a voltage signal
proportional to the transmission oil
temperature.
10 The transmission control unit (D793) Checked by Control unit See section 11 Common electrics , group
supplies voltage to valve block trans- transmission, error shown 11.5.3.9 KIT control unit (D793)
mission control to obtain desired func- with error code.
tion.
11 Solenoid valves for travel direction Checked by Control unit -

and gear position in valve block trans- transmission, error shown
mission control activate gears in the with error code.
transmission and the engine’s power
is transmitted to the transmission’s
output shaft.
12 The turbine speed sensor (B751) Checked by Control unit D12: Diagnostic menu, see section 8 Control sys-
sends the transmission control unit transmission, error shown tem , group 8.4.7.6 TRANSM, menu 6
(D793) a pulse signal with frequency with error code.
proportional to turbine speed.
13 The drum sensor (B752) sends the Checked by Control unit D13: Diagnostic menu, see section 8 Control sys-
transmission control unit (D793) a transmission, error shown tem , group 8.4.7.6 TRANSM, menu 6
pulse signal with frequency propor- with error code.
tional to drum speed.
14 The output shaft speed sensor (B758) Checked by Control unit D14: Diagnostic menu, see section 8 Control sys-
sends the transmission control unit transmission, error shown tem , group 8.4.7.6 TRANSM, menu 6
(D793) a pulse signal with frequency with error code.
proportional to output shaft speed.


15 The torque converter temperature Checked by Control unit D15: Diagnostic menu, see section 8 Control sys-
switch (S221) sends the transmission transmission, error shown tem , group 8.4.7.10 TRANSM, menu 10
control unit (D793) a voltage signal if with error code.
oil temperature in the torque converter
becomes too high.
controls gear shifting according to se- transmission, error shown 11.5.3.9 Transmission control unit (D793)
lected shifting program. with error code.
17 The oil cooler cools the transmission - Oil cooler, description page 49
oil. A thermostat senses the oil’s tem-
perature and directs the oil back to the
transmission if the oil is cold.
18 The transmission control unit (D793) Checked by control sys- See section 11 Common electrics , group
transmits temperature and speed data tem, error shown with error 11.5.3.9 Transmission control unit (D793)
on the CAN bus. code.
19 The KID control unit (D795) shows Checked by control sys- See section 11 Common electrics , group
transmission information in operating tem, error shown with error 11.5.3.12 KID control unit (D795)
menus. code.
20 If the signal from the output shaft - D20: Diagnostic menu, see section 8 Control sys-
speed sensor (B758) indicates that tem , group 8.4.7.6 TRANSM, menu 6
machine speed exceeds the speed
limitation, the transmission control unit
(D793) transmits a engine speed re-
duction request on the CAN bus.
21 The engine control unit (D794) reduc- - See section 11 Common electrics , group
es engine speed. 11.5.3.10 Engine control unit (D794)
22 If the clutch pedal (S220-1) is pressed U = 24 V Section 9 Frame, body, cab and accessories,
down, it sends a voltage signal to the group 9.1 Controls and instruments
cab control unit (D790-1). D22: Diagnostic menu, see section 8 Control sys-
tem , group 8.4.7.1 TRANSM, menu 1
23 The cab control unit (D790-1) trans- Checked by control sys- See section 11 Common electrics , group
mits disengage drive on CAN bus. tem, error shown with error 11.5.3.1 Cab control unit (D790-1)
code.
24 Normally closed (NC) switch, disen- Brake pressure above Normally closed (NC) switch, disengagement,
gagement (S220-2) sends the KDU 0.2 MPa: description page 50
frame control unit (D797-1) a voltage Conn 1, U = 24 V D24: Diagnostic menu, see section 8 Control sys-
signal if brake pressure is high tem , group 8.4.7.1 TRANSM, menu 1
Conn 2, U = 24 V
enough to allow drive disengagement.
Brake pressure below
0.2 MPa:
Conn 1, U = 24 V
Conn 2, U = 0 V
25 The KDU frame control unit (D797-1) Checked by control sys- See section 11 Common electrics , group
transmits disengagement approved tem, error shown with error 11.5.3.2 Frame control unit (D797-1)
on the CAN bus. code.


supplies voltage to valve block trans- transmission, error shown 11.5.3.9 Transmission control unit (D793)
mission control so that drive is disen- with error code.
gaged.

Transmission, function description

page
–
(TE32418)
F 1
5 R
<˚
19 21
D5 D1
D19 D21
20 6, 22 2, 7
D794 D790-1 D790-2
D793 D12 D795 D797-1

10, 15, 17, 25 18 24
D9 D13 D23
Pa
D8 D14
8 9 12 13 14 23
4 Pa ˚C ˚C
16
3 11
009697
The illustration depicts the function description for TE32418

1 The gear selector sends a voltage signal Forward, Conn. F: U = 24 V See section 9 Frame, body, cab and acces-
to the KIT control unit (D790-2). Reverse, Conn. R: U = 24 V sories , group 9.1 Controls and instruments
system , group 8.4.7.2 TRANSM, menu 2
2 The KIT control unit (D790-2) transmits Checked by control system, See section 11 Common electrics , group
the selected direction of travel (forward or error shown with error 11.5.3.11 KIT control unit (D790-2)
reverse) on the CAN bus. code.
3 The transmission’s oil pump pumps oil - -

when the engine is running.
4 The transmission’s oil filter cleans the oil - -

from impurities.


5 The accelerator pedal transmits a signal U = 0.5-4.5 V See section 9 Frame, body, cab and acces-
to the cab control unit (D790-1). sories , group 9.1 Controls and instruments
system , group 8.4.6.1 ENGINE, menu 1
6 The cab control unit (D790-1) transmits Checked by control system, See section 11 Common electrics , group
the desired throttle application on the error shown with error 11.5.3.1 Cab control unit (D790-1)
CAN bus. code.
7 The KIT control unit (D790-2) transmits Checked by control system, See section 11 Common electrics , group
the selected shifting program on the CAN error shown with error 11.5.3.11 KIT control unit (D790-2)
bus. code.
8 The oil pressure sensor sends the trans- Checked by Control unit D8: Diagnostic menu, see section 8 Control
mission control unit (D793) a voltage sig- transmission, error shown system , group 8.4.7.10 TRANSM, menu 10
nal proportional to oil pressure. with error code.
9 The oil temperature sensor sends the Checked by Control unit D9: Diagnostic menu, see section 8 Control
transmission control unit (D793) a voltage transmission, error shown system , group 8.4.7.10 TRANSM, menu 10
signal proportional to transmission oil with error code.
temperature.
10 The transmission control unit (D793) sup- Checked by Control unit See section 11 Common electrics , group
plies voltage to valve block transmission transmission, error shown 11.5.3.9 KIT control unit (D793)
control to obtain desired function. with error code.
11 Solenoid valves for travel direction and Checked by Control unit -

gear position in valve block transmission transmission, error shown
control activate gears in the transmission with error code.
and the engine’s power is transmitted to
the transmission’s output shaft.
12 The turbine speed sensor (B751) sends Checked by Control unit D12: Diagnostic menu, see section 8 Con-
the transmission control unit (D793) a transmission, error shown trol system , group 8.4.7.6 TRANS, menu 6
pulse signal with frequency proportional with error code.
to turbine speed.
13 The drum sensor (B752) sends the trans- Checked by Control unit D13: Diagnostic menu, see section 8 Control
mission control unit (D793) a pulse signal transmission, error shown system , group 8.4.7.6 TRANSM, menu 6
with frequency proportional to drum with error code.
speed.
14 The torque converter temperature switch Checked by Control unit D14: Diagnostic menu, see section 8 Control
(S221) sends the transmission control transmission, error shown system , group 8.4.7.10 TRANSM, menu 10
unit (D793) a voltage signal if oil tempera- with error code.
ture in the torque converter becomes too
high.
15 The transmission control unit (D793) con- Checked by Control unit See section 11 Common electrics , group
trols gear shifting according to selected transmission, error shown 11.5.3.9 KIT control unit (D793)
shifting program. with error code.
16 The oil cooler cools the transmission oil. A - -

thermostat senses the oil’s temperature
and directs the oil back to the transmis-
sion if the oil is cold.


17 The transmission control unit (D793) Checked by control system, See section 11 Common electrics , group
transmits temperature information on the error shown with error 11.5.3.9 KIT control unit (D793)
CAN bus. code.
18 The KID control unit (D795) shows trans- Checked by control system, Section 11 Common electrics, group
mission information in operating menus. error shown with error 11.5.3.12 KID control unit (D795)
code.
19 The crankshaft position sensor provides - See section 11 Common electrics , group
the engine control unit (D794) information 11.5.3.10 Engine control units (D794)
on engine rpm. D19: Diagnostic menu, see section 8 Control
If rpm is so high that it reaches the limit for system , group 8.4.6.6 ENGINE, menu 2
the machine’s speed limitation, the cab
control unit (D790-1) limits engine rpm.
20 The engine control unit (D794) reduces - See section 11 Common electrics , group
engine speed. 11.5.3.10 Engine control units (D794)
21 If the clutch pedal (S220-1) is pressed U = 24 V See section 9 Frame, body, cab and acces-
down, it sends a voltage signal to the cab sories , group 9.1 Controls and instruments
control unit (D790-1). D21: Diagnostic menu, see section 8 Con-
trol system , group 8.4.7.1 TRANSM, menu 1
22 The cab control unit (D790-1) transmits Checked by control system, See section 11 Common electrics , group
disengage drive on CAN bus. error shown with error 11.5.3.1 Cab control unit (D790-1)
code.
23 Normally closed (NC) switch, disengage- Brake pressure above Normally closed (NC) switch, disengage-
ment (S220-2) sends the KDU frame con- 0.2 MPa: ment, description page 50
trol unit (D797-1) a voltage signal if brake Conn 1, U = 24 V D23: Diagnostic menu, see section 8 Con-
pressure is high enough to allow drive dis- trol system , group 8.4.7.1 TRANSM, menu 1
Conn 2, U = 24 V
engagement.
0.2 MPa:
Conn 1, U = 24 V
Conn 2, U = 0 V
24 The KDU frame control unit (D797-1) Checked by control system, See section 11 Common electrics , group
transmits disengagement approved on error shown with error 11.5.3.2 Frame control unit (D797-1)
the CAN bus. code.
25 The transmission control unit (D793) sup- Checked by Control unit See section 11 Common electrics , group
plies voltage to valve block transmission transmission, error shown 11.5.3.9 KIT control unit (D793)
control so that drive is disengaged. with error code.

Transmission shifting, function

page
–
description (TE17312 transmission)

7 9 11 13 15
RSP
25 5
Fwd 2 Rev 1/3
6
8
26 10 12 14 16
18
VFS 1/3
3 4
17
28
27
19
2
1 Fwd 2:nd Rev 1:st 3:rd
008240
29 20 21 22 23 24

1. Bottom strainer oil sump, separates parti- - -
cles from the oil before the pumps.
2. The transmission’s oil pump 1 feeds the 92.1 l/min at 2420 rpm -
transmission with control pressure for con-
trol of the transmission.
3. The oil filter cleans the oil. - -
4. The bypass valve in the filter bracket leads Opening pressure: -

the oil past the filter if the resistance through 390 kPa
the filter becomes too high.
5. The pressure governor releases pressure to Opening pressure: 2500- -

the torque converter if the pressure be- 2900 kPa
comes too high.
6. The pressure reducer reduces the feed 1200 kPa -

pressure to servo pressure.
7. Solenoid valve neutral position (RSP) - Diagnostic menu, see section 8 Control
(Y6066) controls Valve spool neutral posi- system , group 8.4.7.7 TRANSM, menu
tion. 7
8. Valve spool neutral position opens or closes - -

to allow control pressure to the transmis-
sion.
9. Solenoid valve drive forward (Y630) con- 0-1000 mA Diagnostic menu, see section 8 Control
trols Pressure booster drive forward. system , group 8.4.7.8 TRANSM, menu
8 and 8.4.7.9 TRANSM, menu 9
10. Pressure booster forward increases the 0-2000 kPa -

pressure and pressurizes Drive clutch for-
ward.


11. Solenoid valve gear 2 (Y6069) controls 0-1000 mA Diagnostic menu, see section 8 Control
Pressure booster gear 2. system , group 8.4.7.8 TRANSM, menu
12. Pressure booster gear 2 increases the pres- 0-3000 kPa -

sure and feeds Valve spool gear selection
2.
13. Solenoid valve drive reverse controls Pres- 0-1000 mA Diagnostic menu, see section 8 Control
sure booster drive reverse. system , group 8.4.7.8 TRANSM, menu
14. Pressure booster reverse increases the 0-2000 kPa -

pressure and pressurizes Drive clutch re-
verse.
15. Solenoid valve 1/3 (Y6067) controls Pres- 0-1000 mA Diagnostic menu, see section 8 Control
sure booster gear 1/3. system , group 8.4.7.8 TRANSM, menu
16. Pressure booster gear 1/3 increases the 0-2000 kPa -

pressure and feeds Valve spool gear selec-
tion 1/3.
17. Contact drive sends signal to the control -

unit to verify that drive clutches for travel di-
rection and gear selection are activated
when solenoid valve neutral position (RSP)
(Y6066) is activated.
18. Solenoid valve VFS 1/3 (Y6075) controls 0-1000 mA Diagnostic menu, see section 8 Control
servo pressure to Valve spool gear selec- system , group 8.4.7.7 TRANSM, menu
tion 1/3. 7
19. Valve spool gear selection 1/3 pressurizes 0-2000 kPa -

Drive clutch gear 1 or Drive clutch gear 3.
20. Drive clutch forward locks transmission in 0-2000 kPa -

forward drive when the clutch is pressu-
rized.
21. Drive clutch 2nd gear locks transmission in 0-2000 kPa -

2nd gear when the clutch is pressurized.
22. Drive clutch reverse locks transmission in 0-2000 kPa -

reverse drive when the clutch is pressu-
rized.
23. Drive clutch 1st gear locks transmission in 0-2000 kPa -

1st gear when the clutch is pressurized.
24. Drive clutch 3rd gear locks transmission in 0-2000 kPa -

3rd gear when the clutch is pressurized.
25. The safety valve leads the oil back to the Opening pressure: -
sump if the pressure to the torque converter 850 kPa
becomes too high.


26. The torque converter transmits the engine’s - -
power to the transmission.
27. The transmission oil cooler cools the oil. - -
28. The torque converter bypass valve leads Opening pressure:

the oil past the torque converter if the pres- 400 kPa
sure becomes too high.
29. The oil is distributed to different lubrication - -

points in the transmission.

Transmission shifting, function

page
–
description (TE32418 transmission)

Fwd 2/4 Rev 1/3
9 11 13 15
7
RSP
38 6
8
10 12 14 16
5
37 39
18
36 17
19 20 21 22
Rev Fwd VFS 2/4 VFS 1/3
34 35 3 4
23 24 25 26
1/3 2/4
33 2
Fwd 2:nd 4:th Rev 1:st 3:rd
1
27 28 29 30 31 32
008210
1. Bottom strainer oil sump, separates particles from - -
the oil before the pumps.
2. The transmission’s oil pump 1 feeds the transmis- 100.5 l/min at 1973 rpm -
sion with control pressure for control of the trans-
mission.
4. The bypass valve in the filter bracket leads the oil Opening pressure: 410- -
past the filter if the resistance through the filter be- 450 kPa
comes too high.
5. The pressure governor releases pressure to the Opening pressure: 2200 kPa -
torque converter if the pressure becomes too high.
6. The pressure reducer reduces the feed pressure 1200 kPa -

to servo pressure.
7. Solenoid valve neutral position (RSP) (Y6066) - Diagnostic menu, see section 8
controls Valve spool neutral position. Control system , group 8.4.7.7
TRANSM, menu 7
8. Valve spool neutral position opens or closes to al- - -

low control pressure to the transmission.


9. Solenoid valve drive forward (Y630) controls Pres- 0-600 kPa Diagnostic menu, see section 8
sure booster drive forward. Control system , group 8.4.7.8
TRANSM, menu 8 and 8.4.7.9
TRANSM, menu 9
10. Pressure booster forward increases the pressure 0-2000 kPa -

and pressurizes Drive clutch forward.
11. Solenoid valve gear 2/4 (Y6069) controls Pressure 0-600 kPa Diagnostic menu, see section 8
booster gear 2/4. Control system , group 8.4.7.8
TRANSM, menu 9
12. Pressure booster gear 2/4 increases the pressure 0-2000 kPa -
and feeds Valve spool gear selection 2/4.
13. Solenoid valve drive reverse controls Pressure 0-600 kPa Diagnostic menu, see section 8
booster drive reverse. Control system , group 8.4.7.8
TRANSM, menu 9
14. Pressure booster reverse increases the pressure 0-2000 kPa -

and pressurizes Drive clutch reverse.
15. Solenoid valve 1/3 (Y6067) controls Pressure 0-600 kPa Diagnostic menu, see section 8
booster gear 1/3. Control system , group 8.4.7.8
TRANSM, menu 9
16. Pressure booster gear 1/3 increases the pressure 0-2000 kPa -
and feeds Valve spool gear selection 1/3.
17. Contact drive sends signal to the control unit to -

verify that drive clutches for travel direction and
gear selection are activated when solenoid valve
neutral position (RSP) (Y6066) is activated.
18. The drive control valve compares pressure signals - -

from drive clutches for direction of travel and gear
selection and sends the pressure signal on to the
drive contact.
19. The valve spool for reverse drive control opens 0-2000 kPa
when the reverse drive clutch is pressurized and
leads a pressure signal to the drive control valve.
20. The valve spool for forward drive control opens 0-2000 kPa -
when the forward drive clutch is pressurized and
21. Solenoid valve VFS 2/4 (Y6074) controls servo 1200 kPa Diagnostic menu, see section 8
pressure to Valve spool gear selection 2/4. Control system , group 8.4.7.7
TRANSM, menu 7
22. Solenoid valve VFS 1/3 (Y6075) controls servo 1200 kPa Diagnostic menu, see section 8
pressure to Valve spool gear selection 1/3. Control system , group 8.4.7.7
TRANSM, menu 7


23. The valve spool for gear 1/3 control opens when 0-2000 kPa -
valve spool gear selection 1/3 is pressurized and
24. The valve spool for gear 2/4 control opens when 0-2000 kPa -
valve spool gear selection 2/4 is pressurized and
25. Valve spool gear selection 2/4 pressurizes drive 0-2000 kPa -
clutch gear 2 or drive clutch gear 4.
26. Valve spool gear selection 1/3 pressurizes Drive 0-2000 kPa -
clutch gear 1 or Drive clutch gear 3.
27. Drive clutch forward locks transmission in forward - -

drive when the clutch is pressurized.
28. Drive clutch 2nd gear locks transmission in 2nd - -

gear when the clutch is pressurized.
29. Drive clutch 4nd gear locks transmission in 4nd - -

30. Drive clutch reverse locks transmission in reverse - -

drive when the clutch is pressurized.
31. Drive clutch 1st gear locks transmission in 1st gear - -

when the clutch is pressurized.
32. Drive clutch 3rd gear locks transmission in 3rd - -

33. The transmission oil pump pumps oil through the 85.1 l/min at 1973 rpm -
cooler and supplies the torque converter with oil
pressure to run the machine.
35. The bypass valve in the filter bracket leads the oil - -
past the filter if the resistance through the filter be-
comes too high.
36. The oil is distributed to different lubrication points - -

in the transmission.
37. The transmission oil cooler cools the oil. - -
38. The torque converter transmits the engine’s power - -

to the transmission.
39. The safety valve leads the oil back to the sump if Opening pressure: 900 kPa -
the pressure in the torque converter becomes too
high.

Transmission, component locations

page
–
(TE17312)
Left side Right side
3 4 5 6
1 2 7 8
11
10
010282
12 13 14 9
1. Gearbox 8. Oil filling
2. Turbine speed sensor (B751) 9. Oil filter transmission
3. Torque converter 10. Sensor rpm output shaft (B758)
4. Sensor, temperature out to oil cooler 11 Cross-toothed flange (for connection to propeller
shaft)
5 Sensor oil pressure 12 Cooling hoses
6. Engine rpm sensor (input shaft) and oil temperature 13 Thermostat
sensor (B758/766)
7. Sensor, drum rpm (B752) 14 Transmission oil cooler

Transmission, component locations

page
–
(TE32418)
Left side Right side
1 2 3 4 13 14 15 16 17
007036
12 11 10 9 8 7 6 5 8 12
1. Delivery line, oil filter 10. Sensor, drum rpm (B752)
2. Oil dipstick and filler orifice 11 Sensor rpm output shaft (B758)
3. Temperature switch, torque converter 12. Output shaft
4. Engine rpm and oil temperature sensor (from radiator 13. Torque converter
to sump)
5 Transmission oil cooler 14. Valve block transmission control
6. Thermostat 15. Power take-off
7. Cooling hoses 16. Oil pumps, transmission
8. Oil filter transmission 17. Gearbox
9. Turbine speed sensor (B751)

2 3 4 5
009630
9 8 7 6
1. Accelerator pedal (B690) 6. Transmission control unit (D793)

2. Control unit KIT (D790-2) 7. NO switch, declutch (S220-2)
3. Control unit KID (D795) 8. Frame control unit (D797-1)
4. Multi-function lever (S162) 9.
Frame option control unit (D797-2)
5. Control unit cab (D790-1)

Gearbox, replacement (TE17312

page
–
transmission with Volvo TAD760VE

engine)
DANGER
The gearbox is very heavy.
NOTE
Safety.
2 Remove the propeller shaft from the transmission.
3 Detach relevant hoses and cables before separating the engine
and gearbox.
NOTE

4 Remove the screws holding the cover plate to the flywheel.
5 Remove the nuts for the flex plate through the hole under the cov-
er washer.
NOTE
6 Attach the transmission to an overhead crane.
7 Support the engine from underneath with a jack
NOTE
Secure the engine so that it does not tip over when the gearbox
is removed.
8 Remove the screws holding the gearbox to the gearbox mount-
ing.

9 Remove the bolts holding together the transmission and engine.
10 Carefully separate the transmission and engine.
NOTE
Check the balance of the gearbox before lifting it.
NOTE
If the flex plates are damaged during gearbox replacement, they
must be replaced.
11 Remove the gearbox.
007780
Assembly

13 Insert two studs into the flywheel housing as a guide when the
gearbox is installed.
14 Transfer the gearbox mountings to the new gearbox; tighten to
007775
15 Centre a stud on the flywheel so that it aligns with the hole in the
flywheel housing.
007772
16 Lift the gearbox into place. Make sure that the studs on the fly-
wheel come into correct alignment and do not damage the flex
plate.
gine and gearbox to facilitate installation of the nuts for the flex
plate/flywheel.
007776

18 Fit the nuts that fix the flex plates at the flywheel in two steps. First
fit the nuts without tightening. Then rotate the flywheel one more
revolution and tighten the nuts to 46-50 Nm (oiled screw).
NOTE
Turn the engine for each nut to be installed to the flex plate.
20 Measure and check that the gearbox is centred in the frame.

21 Screw the gearbox into the gearbox mountings. Tighten to
169 Nm (oiled screw). Refit the cover plate and propeller shaft.
22 Remove the hoisting equipment from the gearbox.
23 Remove the jack from underneath the engine.
24 Attach relevant hoses and cables to the engine. Check fluid lev-
els and top up as necessary.
25 Calibrate the transmission, see section 8 Control system, group
8.5.2.3 Calibrate DRIVE TRAIN.
007973


page
–

engine and TE32418 transmission
with Volvo TAD952VE engine)
DANGER
NOTE
Safety.
and gearbox.
NOTE

4 Remove the cover washer.
007761
5 Remove the eight screws of the flex plate through the hole under
the cover washer.
NOTE
NOTE
007762
is removed.
ing.

NOTE
NOTE
must be replaced.

Assembly
007769
Gearbox guide stud

15 Lift the gearbox into place. Guide the stud through the flywheel
and out through the hole in the flywheel housing.
plate/flywheel.
007770
screw).
NOTE
NOTE
007762

007895
21 Screw the gearbox into the gearbox mountings. Tighten to 330
Nm (oiled screw). Refit the cover plug and propeller shaft.
007796


page
–

engine)
DANGER
NOTE
Safety.
and transmission.
NOTE
4 Remove the cover plugs in front of the flywheel.

Use the outer hole to rotate the engine.

the cover plug.
NOTE
Rotate the engine for each bolt in the flex plate that has to
be removed.
NOTE
is removed.
ing.
NOTE
NOTE
must be replaced.

Assembly
007769
Gearbox guide stud

screw).
NOTE
NOTE
The engine must be loosened from the engine mounts and
separated from the transmission to remove a dropped bolt.
Secure the bolt in the socket when installing.


Nm (oiled screw).
007796
21 Fit the propeller shaft and cover plugs in front of the flywheel.


page
–
transmission with Cummins QSB6.7

engine and TE32418 transmission
with Cummins QSM11 engine)
DANGER
NOTE
Safety.
and gearbox.
NOTE

008958
5 Remove the screws holding the cover plate to the flywheel on the
left side of the machine.
008314
6 Remove the screws of the flex plate through the hole under the
cover washer.
NOTE
NOTE
008315
is removed.
ing.

NOTE
NOTE
must be replaced.
007780
Assembly
008293
13 Lubricate the converter connection - both on the engine and the

gearbox.
008301

plate/flywheel.
007769
Gearbox guide stud

008319
screw).
NOTE
NOTE
008315


Nm (oiled screw). Refit the cover plug and propeller shaft.
007973

2 Transmission – 2.1 Controls and instruments 39

2.1.1 Gear selector and multi-function
lever
Gear and multi-function lever, description
page
–
Travel direction is selected with the gear and multi-function lever.

F
Selection of travel direction:
• F – Forward
• N – Neutral
• R – Reverse
The switch is supplied voltage by and sends signals to the KIT control
unit (D790-2).
002209
R
Control system , group 8.4.7.2 TRANSM, menu 2.

40 2 Transmission – 2.2 Torque converter/Clutch system
2.2 Torque converter/Clutch

system
2.2.1 Flex plates
Flex plates, changing
page
–

2 Remove the gearbox; see:
• Gearbox, replacement (TE17312 transmission with Volvo
TAD760VE engine) page 20
TAD950VE engine and TE32418 transmission with Volvo
• Gearbox, replacement (TE17312 transmission with Cum-
mins QSB6.7 engine and TE32418 transmission with Cum-
mins QSM11 engine) page 34
3 Remove the bolts holding the flex plate to the transmission.

007774
Fastening the flex plate (TE17312 gearbox with Volvo

TAD760VE engine)

2 Transmission – 2.2.1 Flex plates 41
4 Replace the flex plate. Tighten the screws fixing the flex plate to
the transmission to 40 Nm (oiled screws).
5 Reinstall the gearbox; see:
TAD950VE engine and TE32418 transmission with Volvo
• Gearbox, replacement (TE17312 transmission with Cum-
mins QSB6.7 engine and TE32418 transmission with Cum-
mins QSM11 engine) page 34
6 Before the machine is put into operation, the transmission must
be calibrated; see Transmission, calibration page 50.
007773
Fastening the flex plate (other gearbox and engine al-

ternatives)

42 2 Transmission – 2.6 Lubrication system
2.6 Lubrication system

Lubrication system, description
page
–
The transmission lubrication system has the following function:

• Lubricate gear wheel and bearings
• Apply the clutches in the gearbox
• Cool down the torque converter and gearbox
• Clean the oil of any impurities with two oil filters.
During operation of the engine, the oil pump draws oil from the gear-
box oil sump through a strainer, and it then pumps it through two oil
filters to a control valve.
The control valve supplies oil at the correct pressure to the gearbox
valve housing to activate the clutch plates for FORWARD or RE-
VERSE and gear 1, 2, 3 or 4. The clutch plates require just a small
amount of the oil flow supplied by the pump. The remainder of the oil
is pumped through the torque converter circuit to the oil cooler and re-
turns to the gearbox for lubrication.
See also supplier documentation, transmission.
Transmission oil, changing

page
–
NOTE
Read the safety instructions for oils before working, see section
B Safety.
NOTE
The transmission must not be over filled!
1 Operate and warm up the transmission oil.
3 Remove the drain plug for transmission oil and let the oil drain
into the receptacle.
NOTE
Make sure that the sealing washer stays with the drain plug.
Draining transmission oil

2 Transmission – 2.6 Lubrication system 43
DCF 280-330
Transmission oil filter
4 Remove the oil filter with the filter tool.
5 Lubricate the O-ring on the new oil filter with transmission oil.
6 Install the new filters on the gearbox.
Tighten to contact and then another two-thirds of a turn.
7 When the transmission oil has drained, fit the drain plug.
DCF 370-500
Transmission oil filter

8 Remove the transmission dipstick and fill new transmission oil

through the dipstick’s hole to the marking for low level on the dip-
stick.
For volume and grade, see section F Technical data.
A
B
010112
DCF 280-330
A. Position for filling and level control
B. Dipstick and filler orifice
9 Turn the main current on and start the engine. Allow the engine
to idle for at least two minutes.
10 Check that the drain plug seals completely.
11 Check the transmission oil level with the engine running at idle
and top up to the marking for low level.
A
B
007320
DCF 370-500

2 Transmission – 2.6 Lubrication system 45
12 Warm up the transmission until the operating menu indicates an

oil temperature of 60-65 °C.
a 13 Allow the engine to idle. Check the oil level and fill to the max. oil
level mark.
000356
b
Display information, oil temperature

a. Transmission oil temperature
b. Hydraulic oil temperature
Oil level, check

page
–
NOTE
Read the safety instructions for oils before working, see section
B Safety.
The transmission oil filler pipe and dipstick (position B) is located un-
der the left bonnet.
1 Check the oil level with the engine idling, transmission in neutral
and at working temperature (82-93 °C). The dipstick has two
A markings - MAX and MIN. The oil level should lie between these
B markings.
Wipe off the dipstick before checking.
NOTE
The oil dipstick is long. Wear gloves.
010112
DCF 280-330

2 Fill transmission oil (position B) if needed (for volume, see section

F Technical data).
3 The oil should be filled when the transmission is at operating tem-
perature. Top up – wait a moment – check the dipstick.
NOTE
Work carefully when filling transmission oil to prevent other
fluids or particles from contaminating the oil, which means
A
B risk of transmission damage.
007320
DCF 370-500

2 Transmission – 2.6.3 Oil cooler 47
2.6.3 Oil cooler

Oil cooler, description
page
–
The transmission oil is cooled in the lower section of the cooler assem-
bly.
A temperature-controlled bypass valve, which only acts on the trans-
1 mission oil cooling circuit, is located in a pipe on the underside of the
cooler (engine side). The valve closes when the oil starts to reach
working temperature. This means that the oil reaches normal working
temperature more quickly.
For more detailed information, see supplier documentation, transmis-
sion.
3
003215
Radiator assembly
1. Intercooler
2. Engine radiator

48 2 Transmission – 2.6.3 Oil cooler
Thermostat transmission oil cooler, changing

page
–
NOTE
Safety.

2 Drain the oil from the gearbox; see Transmission oil, changing
page 42.
3 Loosen the cover plug and remove the thermostat.
4 Check the O-ring and the spring in the bottom, change as need-
ed.
5 Install the new thermostat, and the cover plug.
IMPORTANT
007447
It is very important that the thermostat is used with

the temperature bulb facing out as shown.
6 Fill with transmission oil; see Transmission oil, changing page 42.
7 Start the engine and check for leaks.
8 Check the transmission oil level; see Oil level, check page 45.

2 Transmission – 2.7 Cooling system 49
2.7 Cooling system

2.7.3 Oil cooler
page
–
See Oil cooler, description page 47.

50 2 Transmission – 2.8 Transmission control system
2.8 Transmission control system

Transmission, calibration
page
–
See section 8 Control system , group 8.5.2.3 Calibrate DRIVE TRAIN.
2.8.1 Control unit transmission

Transmission control unit, general
page
–
See section 11 Common electrics , group 11.5.3.9 Transmission con-

trol unit and Supplier documentation.
2.8.2 Normally closed (NC) switch,

disengagement
Normally closed (NC) switch, disengagement,
page
–
description
The NC switch for disengagement detects if the wheel brakes are
1 pressurised. The NC switch is located on the distribution block for the
10
2 brake system, above the drive axle’s differential.
1
3 The sensor can be checked from the diagnostic menu, see section 8
3 Control system , group 8.4.7.1 TRANSM, menu 1.
4
5
5
9 6
8 7
007614
1. Brake cooling connection, return from wheel brake

2. Brake cooling connection, return to radiator and
tank
3. Brake cooling connection, to wheel brake
4. Brake cooling connection, from accumulator charg-
ing valve
5. Brake cylinder connection, to wheel brake
6. Brake pressure connection, from brake valve
7. Switch (NC), declutch (S220)
8. NO switch, brake lights (S216)
9. Measurement connection, brake pressure
10. Measuring outlet, brake cooling back pressure

2 Transmission – 2.8.3 Transmission cable harness 51
2.8.3 Transmission cable harness

Transmission cable harness, description
page
–
See section E Schematics.

52 2 Transmission – 2.8.3 Transmission cable harness

3 Driveline/Axle 1
3 Driveline/Axle
Table of Contents 3 Driveline/Axle

mm mm mm mm mm mm
3 Driveline/axle .................................................................................................. 3
3.2 Propeller shaft ............................................................................................ 3
3.3 Drive axle ................................................................................................... 4

2 3 Driveline/Axle

3 Driveline/Axle – 3 Driveline/axle 3
3 Driveline/axle
mm mm mm mm mm mm
3.2 Propeller shaft

Propeller shaft, description
page
–
The propeller shaft transfers engine power from the transmission to

the drive axle. The propeller shaft has two joints, which means that the
engine and drive axle can move in relation to each other.
Propeller shaft, replacement

page
–

2 Clean the contact surfaces (cross-toothed) on the drive axle and
gearbox.
3 Fit the propeller shaft in position with the coupling upward.
4 Fit the propeller shaft attaching bolts.

Tightening torque for DCF 370-500: 156 Nm (oiled screw).
Tightening torque for DCF 280-330: 98 Nm (oiled screw).
Retighten the attaching bolts after 50 operating hours.
007597
Propeller shaft for DCF 370-500

007596
Propeller shaft for DCF 280-330

4 3 Driveline/Axle – 3.3 Drive axle
3.3 Drive axle

Drive axle, general
page
–

The workshop manual only describes components and job descrip-
tions related to installation in the machine. Please refer to the compo-
nent supplier documentation for descriptions and instructions of drive
axle components and systems.
References to component supplier documentation are only provided in
exceptional cases. If information about a component is not found, the
component supplier documentation should be used.
Drive axle, replacement

page
–
DANGER
Drive axle and machine are very heavy.
Under no circumstances go under a machine which

has been lifted by a jack etc. For machine weights,
please refer to section F Technical data.
1 Remove the mast, see section 7 Load handling, group 7.2 Lifting/
lowering.
2 Park the machine with blocks behind the steering wheels.
3 Depressurise the brake and hydraulic systems, see section B
Safety.
4 Turn the start key to position 0 and turn off the main electric
NSpower.
5 Install wedges between the steering axle and frame.

3 Driveline/Axle – 3.3 Drive axle 5
6 Disconnect hydraulic hoses (position 1) and cabling (position 2)

from the distribution block.
NOTE
Plug all unions at once to protect the hydraulic system from
contamination.
004501
2
1. Hydraulic hoses
2. Cables
7 Remove the casing (position 3) on the parking brake.
3
004505
3. Casing parking brake

8 Loosen the lock nut (position 4) and screw in the screw (position
5), this compresses the brake spring. Screw until the brake pads
release from the brake disc. Reinstall the casing on the parking
6 brake (position 3).
9 Detach the hydraulic hose (position 6) of the parking brake.
5 NOTE
4 contamination.
004506
4. Lock nut
5. Release screw
6. Hydraulic hose parking brake

10 Disconnect the propeller shaft from the drive axle. Secure the
propeller shaft, otherwise there is a risk that it will be pulled apart.
11 Lift the machine up so that the frame is lifted away from the axle.
12 Remove the drive wheels from the drive axle.
13 Block up the drive axle under the hubs.
CAUTION
The drive axle may start to roll.
Crushing injury!
Make sure that the drive axle does not roll away when
not under control.
14 Undo the bolts securing the drive axle to the frame.

15 Lift away the drive axle.
CAUTION
Crushing injury!
not under control.

16 Undo the hydraulic hoses on the drive axle.
NOTE
contamination.
17 Transfer the couplings from the old axle to the new axle.
18 Transfer the parking brake union to the new axle.
19 Undo the distribution block bracket and move it to the new axle.
20 Connect the hydraulic hoses from the distribution block to the
drive wheels.

21 Clean the contact surfaces of the drive axle and frame. Also clean
the contact surfaces of the bolts on the underside of the drive ax-
le.
22 Remove the nuts for attaching the drive axle. Blow clean and re-
install the nuts.
23 Transfer the guide pins from the old axle to the new axle.
24 Lift the drive axle into place under the frame.
CAUTION
Crushing injury!
not under control.
25 Lower the frame toward the drive axle. Check that the guide pins
fit in the frame.
26 Fasten the new bolts securing the drive axle in the frame.
• Tighten to 1530 Nm (oiled screw) of DCF 280-330.
• Tighten to 2820 Nm (oiled screw) of DCF 370-500.
27 Install the drive wheels on the new axle.
28 Rustproof the new bolts with suitable paint.

29 Connect the hydraulic hoses (position 1) and cabling (position 2)

to the distribution block on the drive axle.
30 Connect the hydraulic hose to the parking brake, adjust the park-
ing brake.
31 Connect the propeller shaft to the drive axle; see Propeller shaft,
replacement page 3.
32 Check the oil level in the drive axle.
33 Start the machine and bleed the brakes, see section 4 Brakes,
1 group 4.3.9 Wheel brake.
34 Check for leaks.
004501
2
1. Hydraulic hoses
2. Cables


4 Brakes 1
4 Brakes
Table of Contents 4 Brakes

mm mm mm mm mm mm
4 Brakes ............................................................................................................. 3
4.1 Controls and instruments ........................................................................... 3
4.1.1 Brake pedal ............................................................................................ 3
4.3 Power-assisted brake system .................................................................... 6
4.3.1 Hydraulic oil pump ................................................................................. 8
4.3.2 Brake fluid filter .................................................................................... 12
4.3.3 Accumulator charging valve ................................................................. 13
4.3.4 Accumulator ......................................................................................... 17
4.3.5 Brake valve .......................................................................................... 21
4.3.6 Drive axle block ................................................................................... 24
4.3.7 NC (normally closed) switch, brake pressure ...................................... 25
4.3.8 NO (normally open) switch, brake lights .............................................. 27
4.3.9 Wheel brake ......................................................................................... 29
4.3.10 Pipes and hoses .................................................................................. 32
4.3.11 Shuttle valve, dual brake pedals .......................................................... 32
4.5 Parking brake system ............................................................................... 33
4.5.1 Brake fluid pump .................................................................................. 34
4.5.3 M-valve parking brake ......................................................................... 35
4.5.4 Parking brake unit ................................................................................ 36
4.5.5 Parking brake NC switch ..................................................................... 39
4.5.6 Pipes and hoses .................................................................................. 39
4.8 Temperature control, brake fluid cleaning ................................................ 40
4.8.1 Brake fluid tank .................................................................................... 42
4.8.2 Tank heater .......................................................................................... 43
4.8.3 Hydraulic oil pump ............................................................................... 43
4.8.5 Drive axle block ................................................................................... 43
4.8.6 Wheel brake ......................................................................................... 43
4.8.7 Oil cooler .............................................................................................. 44
4.8.8 Thermal bypass valve .......................................................................... 45
4.8.9 Cooling fan ........................................................................................... 46
4.8.10 Sensor brake oil temperature .............................................................. 46
4.8.11 Breather filter, brake fluid tank ............................................................. 47
4.8.13 Pipes and hoses .................................................................................. 49
4.8.14 Brake system fluid ............................................................................... 49

2 4 Brakes

4 Brakes – 4 Brakes 3
4 Brakes
mm mm mm mm mm mm

4.1.1 Brake pedal
Brake pedal, description
page
–
The brake pedal actuates the brake valve via a lever. A spring causes
the pedal to automatically return to its home position.
2 3
000606
Brake pedal, checking and adjusting

page
–
1 Clean the floor round the brake pedal and check that nothing is
obstructing the movement of the brake pedal.
2 Check that the brake pedal springs back adequately and that the
clearance between brake pedal and brake valve is 1–1.5 mm. If
needed, adjust the brake pedal’s stop bolt to correct clearance.
3 Check that the pedal moves easily.
Stop screw for adjusting clearance between brake

pedal and brake valve. (The illustration shows a loose
brake pedal.)

4 4 Brakes – 4.1.1 Brake pedal
4 Lubricate the pedal hinge with "EP2" universal grease.

5 Check that the rubber pad on the brake pedal is intact and that
the pattern is not worn away. Replace as necessary.
6 Check the brake valve; see Brake valve, checking page 21.
Lubrication points, brake pedal. (The illustration

shows a loose brake pedal.)
Brake pedal, replacement

page
–
NOTE
Safety.
1 Turn off the engine and the main electrical power.
Safety.
3 Detach the brake valve from the brake pedal
Secure the brake valve on the cab’s underside and remove the
brake valve attaching bolt.
4 Remove the panel around the steering wheel shaft.
NOTE
There is a variant available with adjustable steering wheel
shaft.

4 Brakes – 4.1.1 Brake pedal 5
5 Detach the steering valve from the pedal bracket.

Secure the steering valve on the cab’s underside. Remove the
steering valve’s attaching bolts. Pull down the valve slightly so
that the steering axle releases from the steering valve.
6 Detach the steering wheel shaft from the brake pedal.
Undo the bolts and pull the steering wheel shaft up slightly so that
the brake pedal can be removed.
7 Detach the clutch pedal from the brake pedal.
8 Remove the brake pedal.
Remove the brake pedal’s attaching bolt and lift away the brake
pedal.
Mounting of steering wheel shaft and steering valve in 9 Transfer the pedal rubber to the new pedal.
pedal bracket.
10 Fit the new brake pedal.
Fit the pedal and fit the pedal’s attaching bolts.
11 Connect the steering valve to the brake pedal.
12 Connect the brake valve to the brake pedal.
13 Fit the clutch pedal to the brake pedal.
14 Close the drain valve on the accumulator charging valve.
NOTE
Check that the accumulator drain valve is fully closed and
15 Grease and adjust the brake pedal, see Brake pedal, checking
and adjusting page 3.
004791

6 4 Brakes – 4.3 Power-assisted brake system
4.3 Power-assisted brake system

Power assisted brake system, function
page
–
description
5
13
B
D790-2 P
T
D10
D797-1
9, 12 D8
10
8
C4 Pa
D11
4 11 15 7
Pa
6
B
ACC
C1 C6
3
P
2 14 T
P
B
B
009634
1 The brake fluid pump pumps fluid See pressure plate on left Hydraulic oil pump, description page 8
from the fluid tank. frame beam.
2 The brake oil filter cleans the oil. - Brake fluid filter, general page 12
3 The accumulator charging valve di- Charge: P = 20.5 ±0.5 MPa Accumulator charging valve, description page
rects oil to charging of accumulators Cooling: P < 0.1 MPa 13
or through the brake system's cool-
ing circuit.
4 The accumulators store oil pressure. See pressure plate on left Accumulator, description page 17
frame beam.
5 The brake valve directs pressure - Brake valve, description page 21
from the accumulators to the brake
cylinders proportional to pressing of
the pedal.
6 The brake cylinders compress the See pressure plate on left Wheel brake, description page 29
discs in the brake unit. frame beam.

4 Brakes – 4.3 Power-assisted brake system 7

7 The wheel brakes brake the ma- - Wheel brake, description page 29
chine.
8 The brake light NO switch (S216) Brake pressure above Switch normally open (NO), brake lights, de-
closes the circuit when the brake cyl- 0.2 MPa: scription page 27
inders are pressurised. Conn 1, U = 24 V D8: Diagnostic menu, see section 8 Control
Conn 2, U = 24 V system, group 8.4.5.4 HYD, menu 4

0.2 MPa:
Conn 1, U = 24 V
Conn 2, U = 0 V
9 The frame control unit (D797-1) Checked by control system, er- Section 11 Common electrics, group 11.5.3.2
transmits the brake light request on ror shown with error code. Frame control unit (D797-1)
the CAN bus.
10 The brake light lamps (H411L and U = 24 V Section 9 Frame, body, cab and accessories,
H411R) are activated by the frame group 9.6.4 Brake lights
control unit (D797-1). D10: Diagnostic menu, see section 8 Control
system, group 8.4.2.8 LIGHTS, menu 8
11 NC switch, brake pressure (S204) Brake pressure above Brake pressure NC switch, description page 25
opens the circuit if the pressure in 11.5 MPa: D11: Diagnostic menu, see section 8 Control
the accumulators is low. Conn 1, U = 24 V system, group 8.4.5.4 HYD, menu 4
Conn 2, U = 24 V
11.5 MPa:
Conn 1, U = 24 V
Conn 2, U = 0 V
12 The frame control unit (D797-1) Checked by control system, er- Section 11 Common electrics, group 11.5.3.2
transmits a warning about low brake ror shown with error code. Frame control unit (D797-1)
pressure on the CAN bus.
13 Control unit KIT (D790-2) activates Checked by control system, er- Section 11 Common electrics, group 11.5.3.11
Warning light brake pressure. ror shown with error code. KIT control unit (D790-2)
14 When one of the brake pedals is ac- - Shuttle valve, dual brake pedals, description
tivated on a machine with reversible page 32
operator’s seat, the pressure signal
runs to the shuttle valve for dual
brake pedals.
15 Shuttle valve, dual brake pedals - Shuttle valve, dual brake pedals, description
sends the pressure signal on to the page 32
wheel brakes, which are applied in
the same way as pos 6–10.
Hydraulic diagram, see section E Schematics group 10 Common hy-

draulics, Basic machine

8 4 Brakes – 4.3.1 Hydraulic oil pump
4.3.1 Hydraulic oil pump

Hydraulic oil pump, description
page
–
The brake system has a vane pump with fixed displacement. The hy-
draulic oil pump sits in the rear of the right main pump. The pump gen-
erates hydraulic power, which is stored in the accumulators for brake
force to the power-assisted brake and parking brake. It also generates
the oil flow used for cleaning and cooling. The switchover between
1 power generation and flow is regulated by the accumulator charging
valve; see Accumulator charging valve, description page 13.
For a description of how a vane pump works, see section 10 Common
hydraulics, group 10.4.3 Vane pump with fixed displacement.
007599
1. Hydraulic oil pump for brake system, cooling and fil-

tration.
Separate brake fluid pump
1
The brake system can be separated from the actual hydraulic system,
at which time it is operated by a separate brake fluid pump (vane pump
with fixed displacement). The separate brake fluid pump is located be-
tween the left main pump and the pump for hydraulic oil cooling and
filtration. The pump generates hydraulic power, which is stored in the
brake force accumulators for the power-assisted brake and parking
brake. It also generates oil flow, which is used for cleaning and cool-
009675
ing. Changeover from power generation and flow is regulated by the

1. Separate brake fluid pump for brake fluid, cooling accumulator charging valve; see Accumulator charging valve, descrip-
tion page 13.
and brake fluid filtration.
For a description of how a vane pump works, see section 10 Common
hydraulics, group 10.4.3 Vane pump with fixed displacement.
Hydraulic oil pump, replacement

page
–
NOTE
Safety.
The hydraulic oil pump for the brake system, cooling and filtering and
the pump for load handling are replaced as a unit. See section 10
Common hydraulics, group 10.4.3 Vane pump with fixed displace-
ment.
Separate brake fluid pump, replacement

–
NOTE
Safety.

4 Brakes – 4.3.1 Hydraulic oil pump 9

2 Clean the pump and the surrounding area.
Safety.
4 Place a receptacle under the gearbox to catch oil spill.
5 Slacken the screws securing the cooling circuit pump and move
it forward.
6 Mark up and detach the hydraulic hoses from the pump.
NOTE
Plug all connections immediately to protect the brake sys-
tem from impurities.
7 Remove the pump.

Remove the attaching bolts, pull the pump forward and lift it
away.
8 Transfer the connection adapters and the contact to the new
pump.
9 Check the O-ring between the brake fluid pump and the pump for
lifting/lowering and tilt. Replace as necessary. Apply silicone
sealant to the sealing surface; see section F Technical data.
10 Fit the brake pump on the main pump.
Position the pump and check that the gear engages on the shaft.
Fit the pump’s attaching bolts.

10 4 Brakes – 4.3.1 Hydraulic oil pump
11 Connect the hydraulic hoses to the brake pump.
NOTE
Check that the O-rings are intact and are fitted correctly.
12 Check the O-ring between the brake fluid pump and the cooling
circuit pump. Replace as necessary. Apply silicone sealant to the
sealing surface; see section F Technical data.
13 Install the cooling circuit pump on the brake pump.
Position the pump and check that the gear engages on the shaft.
NOTE
15 Turn on the main electric power and start the engine.
16 Check that the hose connections and seal between the hydraulic
oil pumps are free of leaks.
Check the feed pressure from the brake pump.
17 Remove the receptacle. Treat spill oil as environmentally hazard-
ous waste.
004791
18 Check the oil level in the brake system, fill as necessary.
NOTE
If the pump is replaced due to malfunction, change the oil
and filter in the brake system as well.
Hydraulic oil pump and separate brake fluid pump,

–
check
NOTE
Safety.

4 Brakes – 4.3.1 Hydraulic oil pump 11
Checking pump pressure

1 Operate and warm up the machine so that the oil in the brake sys-
tem reaches operating temperature, at least 50 °C.
2 Machine in service position, see section B Safety
Safety.
4 Connect a pressure gauge (0–25 MPa) to the pump pressure
measuring outlet on the accumulator charging valve.
5 Start the engine and run it at idling speed.
005146
Measuring outlet, pump pressure

6 Close the drain valve on the accumulator charging valve and
check the pump pressure during charging.
NOTE
During charging, the pressure should increase to 20.5 ±0.5 MPa
before the accumulator charging valve switches to cooling. When
the accumulator charging valve switches to cooling, the pressure
drops.
7 Check the pressure during cooling.
004791
During cooling the pressure should be max. 0.10–0.15 MPa at

max. engine rpm.
Close the accumulator charging valve
8 Stop the engine
Safety.
10 Remove the pressure gauge and fit the protective cap on the
measuring outlet.
NOTE

12 4 Brakes – 4.3.2 Brake fluid filter
Checking accumulator charging

1 Operate and warm up the machine so that the oil in the brake sys-
tem reaches operating temperature, at least 50 °C.
Safety.
4 Connect a pressure gauge (0–25 MPa) to the measuring outlet
for accumulator pressure on the accumulator charging valve.
004810
Measuring outlet, accumulator pressure

NOTE
7 Check that the pressure rises slowly to 20.5 ±0.5 MPa.
8 Brake repeatedly and check at which pressure the accumulator
charging valve switches to charging.
The valve must switch to cooling at 15.5 ±0.5 MPa.
Safety.
004791
Close the accumulator charging valve measuring outlet.
NOTE
4.3.2 Brake fluid filter

Brake fluid filter, general
page
–
See Brake fluid filter, description page 48.

4 Brakes – 4.3.3 Accumulator charging valve 13
4.3.3 Accumulator charging valve

Accumulator charging valve, description
page
–
The accumulator charging valve distributes oil from the brake fluid
3 4 5 6
pump between pressure storage and cooling of the wheel brakes. The
accumulator charging valve is located on the left of the frame in the
area beside the gearbox.
The accumulator charging valve stores pressure by guiding the oil to
the accumulators. The wheel brakes are cooled by directing oil to the
drive axle cooling circuit and then on to the hydraulic oil tank. In ma-
chines with separate brake fluid tank and cooler, the oil passes from
the drive axle cooling circuit via the brake system cooler back to the
brake fluid tank.
The accumulator charging valve prioritises charging of the accumula-
tors above cooling. A restriction of the charging means that a small
quantity of oil also flows to cooling during accumulator charging. At
idling speed the flow from the pump is so small that all oil flows to pres-
sure storage.
The drain valve (position 11) is used to relieve the pressure in the ac-
2 1 13 12 11 10 9 8 7 cumulators to the tank. The valve opens a connection between the ac-
cumulators and the wheel brake’s cooling circuit. The oil is drained
through the wheel brake to the tank.
There is a measuring outlet for measuring accumulator pressure (po-
sition 5) and pump pressure (position 4) on the accumulator charging
valve. The pressures are individual to each machine and are on the
pressure plate on the left-hand frame beam, see section 10 Common
hydraulics. On the accumulator charging valve, there is also a sole-
noid valve, parking brake (position 6), switch (NC) brake fluid pressure
(position 9) and switch (NC) parking brake (position 7).
• Solenoid valve parking brake, description page 35
007600
• Switch normally open (NO), brake lights, description page 27

• Parking brake NC switch, description page 39
1. Safety valve (22 MPa)
2. Connection from pump (P)
3. Wheel brake connection (T)
4. Measuring outlet, pump pressure (P)
5. Measuring outlet, accumulator pressure (M)
6. Solenoid valve, parking brake (Y642)
7. NC (normally closed) switch, parking brake (GHB)
(S200)
8. Accumulator connection (ACC)
9. NC (normally closed) switch, brake fluid pressure
(LB) (S204)
10. Connection, parking brake calliper (HB)
11. Drain valve
12. Main valve, charging
13. Pressure limiting valve

14 4 Brakes – 4.3.3 Accumulator charging valve
Accumulator charging, checking and adjustment

page
–
NOTE
Safety.
1 Operate and warm up the machine so that the brake fluid reaches
operating temperature, at least 50 °C.
Safety.
4 Connect a pressure gauge (0-25 MPa) to the measuring outlet for
accumulator pressure on the accumulator charging valve.
004810
7 Check that the maximum pressure corresponds with the accumu-

lator pressure on the pressure plate on the left frame beam.
MPa
MPa
MPa
MPa
MPa MPa MPa MPa

007604
M Pa

4 Brakes – 4.3.3 Accumulator charging valve 15
8 If necessary, adjust the accumulator charging pressure on the

pressure limiting spool.
Undo the lock nut and adjust the pressure by turning the adjusting
screw.
Anticlockwise: reduce pressure.
Clockwise: increase pressure.
9 Open the drain valve on the accumulator charging valve so that
the accumulators are drained and the valve switches to charging.
Close the valve and check the max. pressure again.
10 Repeat steps 8-10 until the accumulator pressure matches the
data on the pressure plate.
Safety.
measuring outlet.
004811

14 Fit the cover plates over the area at the gearbox.
Accumulator charging valve, replacement

page
–
NOTE
Safety.
Safety.
3 Mark the hydraulic hoses and electric cables as illustrated.
1 C
4 Detach the wiring from the accumulator charging valve.
5 Detach and plug all hydraulic hoses from the accumulator charg-
ing valve.
4
Remove the parking brake valve (C) for easier access.
B
3
NOTE
004812
2 A 5

16 4 Brakes – 4.3.3 Accumulator charging valve
6 Remove the accumulator charging valve.

7 Transfer the connection adapters and sensors to the new accu-
mulator charging valve.
8 Fit the new valve.
004813
9 Connect the hoses to the accumulator charging valve in accord-

1 C ance with the marking.
NOTE
4 Check that the O-rings are intact and are fitted correctly.
B 10 Fit the parking brake valve and parking brake NO switch.

11 Connect the wiring to the accumulator charging valve.
3
004812
2 A 5

Check that the hydraulic connections are sealed tightly.
14 Check the charging and changing function, see Accumulator
charging, checking and adjustment page 14.
004791

4 Brakes – 4.3.4 Accumulator 17
4.3.4 Accumulator
Accumulator, description
page
–
The accumulators store pressure so that there is a pressure reserve

in the event of engine or brake system malfunction. The brake system
has four accumulators connected in parallel. These are located along
the frame beam on the left side of the machine.
The accumulators are of the diaphragm type. Each accumulator is di-
vided into two spaces by a diaphragm. One side of the diaphragm is
pressurized by nitrogen gas. The other side is pressurized by the hy-
draulic oil, which compresses the nitrogen gas.
At the top of the accumulator, there is a connection for checking nitro-
gen gas pressure (and for filling nitrogen gas using special filling
equipment).
When the accumulator is filled with hydraulic oil the diaphragm is
pressed up and the pressure of the nitrogen gas rises. When the hy-
draulic system requires supply from the accumulator, the diaphragm
forces the oil back into the system.
009676
Pressurised oil from the accumulator is used for the service and park-
Brake system accumulators ing brake systems and for supplying the servo hydraulics’ reducing
valve (see section 4 Brakes and section 7 Load handling).
NOTE
If the accumulator delivers low oil pressure, the pumps may be
damaged and the hydraulic functions may cease to work.
Accumulator, checking
page
–
NOTE
Safety.
NOTE
A special tool for checking the accumulators can be ordered from
Kalmar Industries. The procedure without use of the special tool
is described below.
Safety.
3 The accumulators can be tested with separate test equipment or
in the machine. Primarily, separate test equipment should be
used since it is faster and more exact.
Test equipment can be ordered from Kalmar Industries AB.
• Test with test equipment: continue with step 4.
• Test in machine: continue with step 6.

18 4 Brakes – 4.3.4 Accumulator
Checking with test equipment

4 Remove the accumulators and test them with the intended test
equipment.
MPa
The accumulators’ gas pressure should match with the pressure

plate.
MPa
5 Continue with step 17.
MPa
MPa
MPa MPa MPa MPa
007604
M Pa
Pressure plate, gas pressure brake accumulators
Checking in machine
2 3 6 Detach three of the accumulators from the distribution block (po-

1
sition 3). Plug the distribution block connections with plugs that
can handle high pressure. Plug the connections on the accumu-
lators to protect against contamination.
009677
1. Screw
2. Clamp
3. Distribution block

4 Brakes – 4.3.4 Accumulator 19
7 Connect a pressure gauge (0–25 MPa) to the measuring outlet

for accumulator pressure on the accumulator charging valve.
9 Close the drain valve on the accumulator charging valve and
charge the accumulator until the accumulator charging valve
changes to cooling.
NOTE
Check that the accumulator drain valve is fully closed and tighten
the lock ring.
10 Check that the plugs seal properly.
11 Stop the engine
12 Lower the pressure by means of braking carefully several times
while checking the pressure on the pressure gauge.
004810
When the pressure reaches approx. 10 MPa the pressure must

decrease immediately to 0 MPa.
If the pressure drops immediately when the engine is shut off,
then the accumulator does not have any pre-charge pressure.
This indicates internal leakage and the accumulator must be
changed.
If the pressure can be reduced slowly to a pressure below
10 MPa then the precharge pressure is too low and the accumu-
lator must be replaced or given to authorised personnel for main-
tenance.
Safety.
14 Mark up and disconnect the tested accumulator. Plug the con-
nections. Connect one of the other accumulators to the distribu-
tion block.
15 Repeat steps 8 - 14 until all accumulators have been checked.
Safety.
Installing and final checking

17 Connect all accumulators to the distribution blocks. If needed, re-
place or fill defective accumulators.
NOTE
Check that the seals are intact and are fitted correctly.
19 Close the drain valve on the accumulator charging valve so that
the accumulators are charged.
NOTE
Check that the accumulator drain valve is fully closed and tighten
the lock ring.
20 Check that the accumulators’ connections are sealed tightly.

20 4 Brakes – 4.3.4 Accumulator
21 When the accumulators are fully charged, shut off the engine and
turn the start key to position I.
22 Check that at least 8 brake applications (pedal depressions) can
be performed before the pressure drops to 10 MPa.
At 11.5 MPa the warning lamp for low brake pressure must come
on.
Accumulator, replacement
page
–
NOTE
Safety.
Safety.
2 3 4 Slacken and remove the screw (position 1) holding the accumu-

1
lator clamp (position 2) together.
5 Detach the accumulator from the distribution block (position 3).
NOTE
Hold the block firmly so that the other accumulator does not
work loose.
6 Bend the clamp away and remove the accumulator.
7 Fit the new accumulator.
NOTE
009677
Check that the seal is intact and is fitted correctly.
1. Screw 8 Secure the accumulator’s clamp and tighten the bolt.

2. Clamp
11 Check that the accumulator's connection is sealed tightly.
12 Check precharging and function, see Accumulator, checking
page 17 steps 18-19.
004791

4 Brakes – 4.3.5 Brake valve 21
4.3.5 Brake valve

Brake valve, description
page
–
The brake valve, which is located on the underside of the cab under-
3
neath the brake pedal, controls the hydraulic pressure to the brakes.
2 A lever transfers pedal force to the valve.
1 The brake valve is a mechanically activated proportional valve. This
means that the resistance in the brake valve increases in proportion to
brake pressure. This provides optimum pedal responsiveness and in-
creased safety as the operator senses if no brake pressure is being
built up (no resistance in the pedal).
007605
1. Inlet from accumulators [P]

2. Return connection [T]
3. Outlet to brake cylinders [B]
Brake valve, checking

page
–
NOTE
Safety.
1 Operate and warm up the machine so that the brake fluid reaches
Safety.
brake pressure on the distribution block on the front axle.
NOTE
6 Start the machine and run it at idling speed until the accumulators
are charged and the accumulator charging valve changes to
cooling.
7 Press down the pedal completely and read off the pressure.
Compare to the pressure plate on the left frame member.
8 Stop the engine
9 Depress the pedal fully and keep it pressed down, check the
pressure.

22 4 Brakes – 4.3.5 Brake valve
The brake pressure must correspond with the value specified on

the pressure plate and must not decrease from this value for 15
seconds.
10 Release the pedal, the brake pressure must decrease to 0 MPa
immediately. Otherwise the brake valve is not sealed and can
cause the brakes to remain applied and then overheat during op-
eration.
Replace the brake valve if it is not sealed.
Safety.
measuring outlet.
NOTE
Brake valve, replacement

page
–
NOTE
Safety.
Safety.
3 Mark up and detach the hydraulic hoses from the brake valve.
B
T NOTE
P
Plug the connections immediately to protect the brake sys-
4 Secure the brake valve under the cab.
007606

4 Brakes – 4.3.5 Brake valve 23
5 Remove the brake valve attaching bolt.

6 Remove the brake valve.
7 Transfer the connection adapters to the new brake valve.
8 Install the new brake valve.
NOTE
Remember the spacer ring.
9 Connect the hydraulic hoses to the brake valve in accordance

B with the marking.
T
NOTE
P
10 Grease and adjust the brake pedal, see Brake pedal, checking
and adjusting page 3.
004795

12 Turn on the main electric power and start the engine. Run the en-
gine at idling speed.
13 Test the brakes a couple of times.
14 Check that the brake valve's connections are sealed tightly.
15 Bleed the wheel brakes' brake cylinders, see Wheel brakes,
bleeding page 30.
004791

24 4 Brakes – 4.3.6 Drive axle block
4.3.6 Drive axle block

Drive axle block, description
page
–
The drive axle block distributes oil flow and brake pressure to the right
1 and left-hand wheel brakes. The drive axle block is located on a brack-
10
2 et above the drive axle differential.
1
3 The drive axle block has a measuring outlet for brake pressure and for
3 measuring back pressure in the disc brake’s cooling circuit.
4
The drive axle block has a bypass valve which guides oil directly from
5
5 the cooling circuit intake to the cooling circuit return if the resistance in
9 the axle becomes too great. This protects the wheel brake seals, e.g.
6 when the oil is cold.
8 7 The drive axle block houses two switches - brake light NO (normally
open) switch (S216), see Switch normally open (NO), brake lights, de-
scription page 27, and declutch NO switch (S220), see section 2
Transmission, group 2.8.2 Normally closed (NC) switch, disengage-
ment.
007614
1. Brake cooling connection, return from wheel brake

2. Brake cooling connection, return to radiator
3. Brake cooling connection, to wheel brake
4. Brake cooling connection, from accumulator charg-
ing valve
5. Brake cylinder connection, to wheel brake
6. Brake pressure connection, from brake valve
7. NO switch, declutch (S220)
8. NO switch, brake lights (S216)
9. Measurement connection, brake pressure
10. Measuring outlet, brake cooling back pressure

4 Brakes – 4.3.7 NC (normally closed) switch, brake pressure 25
4.3.7 NC (normally closed) switch, brake

pressure
Brake pressure NC switch, description
page
–
The brake pressure NC (normally closed) switch, (S204) detects the

pressure in the accumulators. The NC switch is located on the accu-
mulator charging valve to the left on the frame in the space at the gear-
box.
When the pressure in the feed circuit is high enough to ensure braking
of the machine, the sensor closes an electric circuit. This is used to
warn for pressure-drop in the brake system. The sensor’s opening
pressure is chosen so that there is pressure for another 8 brake appli-
cations without additional feed from the pump after the light has gone
off.
The brake pressure NC (normally closed) switch (S204) is supplied
voltage by the frame control unit (D797-1). When the pressure rises
over the opening pressure, a voltage signal is sent to the frame control
unit (D797-1).
Control system, group 8.4.5.4 HYD, menu 4.
007608
Break-contact brake pressure, adjusting

page
–
NOTE
Safety.
1 Operate and warm up the machine until the oil reaches operating
temperature, at least 50 °C.
Safety.

26 4 Brakes – 4.3.7 NC (normally closed) switch, brake pressure

accumulator pressure on the accumulator charging valve.
NOTE
6 Start the engine and fully charge the accumulators (the accumu-
lator charging valve changes to cooling).
7 Stop the engine and turn the starter key to position I.
8 Brake several times, stop when the warning lamp for low brake
pressure comes on.
9 Read off the accumulator pressure. The pressure should be ap-
prox. 11.5 MPa.
004810
10 If necessary, adjust the warning level by turning the adjusting

screw in the rear edge of the sensor, between the contact pins.
NOTE
The setting is very sensitive, turn max. 1/4 turn at a time.
11 Repeat steps 6-10 until the warning lamp comes on at 11.5 MPa.
12 Seal the adjusting screw with locking fluid.
Safety.
measuring outlet.
NOTE

4 Brakes – 4.3.8 NO (normally open) switch, brake lights 27
4.3.8 NO (normally open) switch, brake

lights
Switch normally open (NO), brake lights, description
page
–
The brake light NO switch controls brake light activation when the ma-
chine brakes. The switch is located on the drive axle block which sits
on a bracket above the drive axle differential.
The brake light NO switch (S216) is supplied voltage by and sends a
voltage signal to the frame control unit (D797-1). When the pressure
increases above the closing pressure, a voltage signal is sent to the
frame control unit (D797-1).
The signal can be checked from the diagnostic menu, see tab 8 Con-
trol system, group 8.4.5.4 HYD, menu 4.
007609

28 4 Brakes – 4.3.8 NO (normally open) switch, brake lights
Brake light NO switch, checking

page
–
NOTE
Safety.
1 Operate and warm up the machine until the brake fluid reaches
3 Brake and check that the brake light comes on.
Safety.
brake pressure on the distribution block.
NOTE
7 Start the engine.
8 Use the display, go to the diagnostic menu, see section 8 Control

DIAG HYDRAULIC 4(6) system, group 8.4.5.4 HYD, menu 4.
PRESSURE SWITCHES
BRAKE PRESSURE X BRAKE LIGHT PRESS. indicates status for the brake light con-
BRAKE LIGHT PRESS. X tact. 1 = Activated contact (brakes applied).
007123
DECLUTCH PRESSURE X 9 Press down the brake pedal slowly until the brake light is activat-
ed or the status of the input signal changes. Keep the pedal in this
position and check the pressure on the pressure gauge.
The status can be changed and the brake light should come on
when the pressure is approx. 0.2 MPa.
10 Stop the engine
Safety.
measuring outlet.
NOTE

4 Brakes – 4.3.9 Wheel brake 29
4.3.9 Wheel brake

Wheel brake, description
page
–
The wheel brakes brake the machine during operation and are located
on the drive axle between the drive axle housing and hub reduction.
The wheel brake uses so-called wet disc brakes (WDB). Wet disc
brakes require minimal maintenance and have a long service life due
to effective cooling. Maintenance requirements are minimised since oil
circulates in the brake system and prevents corrosion.
007615
The wheel brakes have two main sections - disc assembly and brake
1 2
cylinder. The disc assembly performs the braking. The brake cylinder
presses the discs in the disc assembly together during braking.
000016
Wheel hub and brake, cross section

1. Disc assembly
2. Brake cylinder

30 4 Brakes – 4.3.9 Wheel brake
Wheel brakes, bleeding

page
–
NOTE
Safety.
IMPORTANT
Both the brake cylinder and disc brake must be bled
after work where the brake system is opened or after
work on the wheel brake.
Brake cylinder
2 Place a ring spanner on the bleed nipple and connect a transpar-
ent hose to the bleed nipple.
Direct the other end of the hose down into a receptacle.
3 Start the machine and press down on the brake pedal; keep the
pedal pressed down.
4 Open the bleed nipple and allow oil to run out of it until the oil is
free of air bubbles.
NOTE
The hydraulic hose between the brake pedal and brake is
approx. 7 metres long. Therefore, allow at least two litres of
oil to pass through the bleed nipple when bleeding to ensure
that no air pockets remain in the system.
Bleed nipple, brake cylinder, on top of the drive axle at 5 Close the bleed nipple.
the wheel hub's inner short side (left-hand side).
6 Move the spanner and hose and repeat steps 1–4 on the other
side.
7 Check the oil level in the brake system, fill as necessary.
Disc brake
NOTE
Disc brake ventilation is vital to correct cooling of the discs.
1 Start the engine and allow it to idle. Wait until the brake accumu-
lators are fully loaded and the accumulating charging valve has
switched to brake cooling.

4 Brakes – 4.3.9.1 Disc assembly 31
2 Remove the bleed screw of the disc brake and let oil flow out of
the hole until it is free of air bubbles. Refit the bleed screw.
3 Repeat steps 1-3 on the other wheel.
Bleed nipple, disc brake, on top of the drive axle at the

wheel hub’s inner short side (left-hand side).
Wheel brake, replacement

page
–
See supplier documentation, drive axle.
4.3.9.1 Disc assembly

Disc assembly, description
page
–
The disc assembly consists of several thin metal discs fixed alternately
to the wheel brake housing and to the hub reduction housing. The
discs are mounted on splines, which allows them to move laterally.
Oil circulates between the discs cooling them, thus the name wet disc
brake. The oil is the same as in other parts of the brake system.
Braking is effected by the brake cylinder pressing together the discs.
This creates friction between the discs that are fixed to the axle and
those fixed to the hub reduction.
000008
Disc assembly

32 4 Brakes – 4.3.9.2 Brake cylinder
4.3.9.2 Brake cylinder

Brake cylinder, description
page
–
The brake cylinder is integrated in the wheel brake and consists of a

metal ring (cylinder) with two seal rings. The seals have lateral support
from a bevel on the cylinder and a bevel on the wheel brake housing.
The space between the seal rings is pressurized through a channel in
the wheel brake housing. The pressure moves the metal ring sideways
and compresses the disc assembly.
000007
Brake cylinder
4.3.10 Pipes and hoses

Piped and hoses, description
page
–
See section 10 Common hydraulics, group 10.5.1 Pipes and hoses.
4.3.11 Shuttle valve, dual brake pedals

Shuttle valve, dual brake pedals, description
page
–
See section 10 Common hydraulics, group 10.5.3 Shuttle valve.

4 Brakes – 4.5 Parking brake system 33
4.5 Parking brake system

Parking brake system, function description
page
–
D5
5
6 12
D790-1 D790-2
D797-1
7 11
D7 D10
4
C4 8
Pa 10 9
ACC
C1 3
H
P
2 T
009635
1 The brake fluid pump pumps fluid from P = 21 ±1 MPa Brake fluid tank, description page 42
the brake fluid tank. Hydraulic oil pump, description page 8
2 The brake fluid filter cleans dirt from the - Brake fluid filter, description page 48
oil.
3 The accumulator charging valve directs Charge: P = 20.5 Accumulator charging valve, description
oil to charging of accumulators or through ±0.5 MPa page 13
the brake system's cooling circuit. Cooling: P < 0.1 MPa
4 The accumulators store oil pressure. See pressure plate on left Accumulator, description page 17
frame beam.
5 Switch parking brake (S107) activates Switch activated: Section 9 Frame, body, cab and accesso-
parking brake. Conn 1, U = 24 V ries, group 9.1 Controls and instruments
The switch uses two signals - one for ap- Conn. 7, U = 0 V D5: Diagnostic menu, see section 8 Con-
plied and one for released parking brake. trol system, group 8.4.5.5 HYD, menu 5
Switch in resting position:
Both signals must be correct to enable re-
lease of the parking brake. Conn. 1, U = 0 V
Conn. 7, U = 24 V
6 The cab control unit (D790-1) transmits Checked by control sys- Section 11 Common electrics, group
Activate parking brake on the CAN bus. tem, error shown with er- 11.5.3.1 Cab control unit (D790-1)
ror code.

34 4 Brakes – 4.5.1 Brake fluid pump
7 The frame control unit (D797-1) activates U = 24 V Solenoid valve parking brake, description
the parking brake solenoid valve (Y642). page 35
D7: Diagnostic menu, see section 8 Con-
trol system, group 8.4.5.5 HYD, menu 5
8 Solenoid valve parking brake (Y642) af- Pump pressure Solenoid valve parking brake, description
fects the valve spool which drains pres- page 35
sure in the parking brake calliper to tank.
9 The brake caliper is drained of pressure 0 MPa Parking brake unit, description page 36
and the spring applies the parking brake.
10 The parking brake NC switch (S200) Applied parking brake: Parking brake NC switch, description page
opens the circuit when the pressure in- Conn 1, U = 24 V 39
creases. D10: Diagnostic menu, see section 8 Con-
Conn. 2, U = 0 V
trol system, group 8.4.5.5 HYD, menu 5
Released parking brake:
Conn 1, U = 24 V
Conn 2, U = 24 V
11 The frame control unit (D797-1) transmits Checked by control sys- Section 11 Common electrics, group
Parking brake applied on the CAN bus. tem, error shown with er- 11.5.3.2 Frame control unit (D797-1)
ror code.
12 The KIT control unit (D790-2) activates Checked by control sys- Section 9 Frame, body, cab and accesso-
the parking brake indicator light (508). tem, error shown with er- ries, group 9.1 Controls and instruments
ror code.
Hydraulic diagram, see section E Schematics, group 10 Common hy-

4.5.1 Brake fluid pump

Brake fluid pump, description
page
–
See Hydraulic oil pump, description page 8.

Brake fluid filter, general
page
–
See Brake fluid filter, description page 48.

4 Brakes – 4.5.3 M-valve parking brake 35
4.5.3 M-valve parking brake

Solenoid valve parking brake, description
page
–
The parking brake solenoid valve (Y642) activates the parking brake.
The solenoid valve sits on the accumulator charging valve, which is lo-
cated to the left on the frame in the space at the gearbox; see Accu-
mulator charging valve, description page 13.
The solenoid valve opens a connection between the accumulators and
the parking brake calliper at activation. This means that the parking
brake calliper is pressurised and the parking brake is disengaged.
When the voltage feed to the solenoid valve is cut off, the connection
between the accumulators and parking brake calliper is terminated. In-
stead, a connection between the parking brake calliper and tank is
opened and the parking brake applied. This means that the parking
brake is applied if the machine loses electrical power or if the brake
system becomes depressurised.
The solenoid valve is supplied with voltage by the frame control unit
(D797-1) at activation.
007611
Solenoid valve parking brake, checking

page
–
DANGER
The machine may start to roll.
Risk of crushing.
Block the wheels so that the machine cannot start to

roll when the parking brake is released.
1 Start the engine and run the engine at idling speed until the warn-
ing lamp for brake pressure goes out and the accumulator charg-
ing valve changes to cooling.
2 Turn off the engine and turn the start key to position I.
3 Release the parking brake with switch parking brake and check
that the parking brake’s brake caliper releases. The brake caliper
should be able to move.
4 Activate the parking brake with the parking brake switch and
check that the parking brake’s brake caliper is applied.

36 4 Brakes – 4.5.4 Parking brake unit
4.5.4 Parking brake unit

Parking brake unit, description
page
–
The parking brake unit keeps the machine stationary when parked.
3 1 2
The parking brake unit is located on the drive axle input shaft between
the propeller shaft and drive axle.
The parking brake acts on the propeller shaft via a disc mounted on
the drive axle input shaft and a brake calliper with dry brake pads
mounted in a bracket on the drive axle.
NOTE
If the hydraulic pressure in the feed circuit drops, a warning is ac-
tivated before the pressure drops so low that the parking brake is
applied. If the parking brake is applied while the machine is on the
move, the brake disc and brake pads must be checked and re-
placed if necessary.
007612
1. Protective cap over adjusting screw

2. Parking brake calliper
3. Parking brake disc
Parking brake unit, checking and adjusting
–
DANGER
Risk of crushing.

1 Start the engine and run up hydraulic pressure until the accumu-
lators are fully charged and the accumulator charging valve
switches to cooling.
2 Turn off the engine and turn the start key to position I.
3 Release the parking brake.
4 Check that the parking brake caliper can move on the bracket.
5 Check that the brake disc is free from oil and dirt.

4 Brakes – 4.5.4.1 Parking brake caliper 37
6 Remove the cover from the brake caliper.
7 Undo the lock nut.

8 Adjust the adjustment screw so that the brakes are applied.
9 Turn back the adjusting screw so that the clearance between pad
and disc is 0.5±0.1 mm.
10 Tighten lock nut.
NOTE
To avoid turning the adjustment screw as well it must be
held still when tightening the lock nut.
11 Refit the cover to the caliper.
12 Test the operation of the parking brake.
4.5.4.1 Parking brake caliper

Brake calliper, description
page
–
The brake calliper has a spring section and a hydraulic section. The
1 2 3 4 5
spring section applies the brake while the hydraulic section is used to
release the brake. This means that the parking brake is applied if the
brake system loses pressure. This, in turn, means that the machine is
braked if a serious fault arises.
000020
1. Brake pads
2. Release cylinder
3. Application spring
4. Release screw
5. Adjusting washer

38 4 Brakes – 4.5.4.2 Parking brake pads
4.5.4.2 Parking brake pads

Brake pads, description
page
–
The brake pads consist of a metal plate with friction material (lining).
Brake pads, replacement

page
–
DANGER
Risk of crushing.

1 Machine in service position and wheels blocked, see section B

Safety.
2 Remove the cover from the brake caliper.
3 Undo the lock nut.

4 Slacken the adjusting screw to release the brake pads.
5 Remove the split pin and undo the nut on one of the attaching
bolts holding the parking brake calliper in place.

4 Brakes – 4.5.4.3 Parking brake disc 39
6 Pull the attaching bolt out so that the brake pads can be angled
out and removed.
NOTE
The bolt does not need to be removed.
7 Remove the parking brake pads.
8 Clean the brake disc with methylated spirit.
9 Install new parking brake pads.
10 Press the attaching bolt back.
11 Fit the nut and a new split pin.
12 Adjust the parking brake, see Parking brake unit, checking and
adjusting page 36.
4.5.4.3 Parking brake disc

Brake disc, description
page
–
The brake disc is mounted on the drive axle input shaft. The drive ax-
le’s gear ratio amplifies the braking force.
4.5.5 Parking brake NC switch

Parking brake NC switch, description
page
–
The parking brake NC switch (S200) detects whether the parking

brake is applied or released. The NC switch sits on the accumulator
charging valve, which is located to the left on the frame in the space at
the gearbox; see Accumulator charging valve, description page 13.
Break-contact parking brake (S200) senses the pressure in the park-
ing brake circuit. When the pressure is so high that the parking brake
is released, the sensor opens an electric circuit. This is used to indi-
cate that the parking brake is released.
The parking brake NC switch (S200) is supplied power by and sends
a voltage signal to the frame control unit (D797-1). When the pressure
increases above the opening pressure, the voltage signal to the frame
control unit (D797-1) is cut off.
NOTE
Gears cannot be engaged when the parking brake is applied.
007613

page
–

40 4 Brakes – 4.8 Temperature control, brake fluid cleaning
4.8 Temperature control, brake

fluid cleaning
Temperature control, brake fluid cleaning,
page
–
function description
Brake system
11
D795
D797-1
D8 9
D10
C1 C3
3 4
P T
2 5
6 10
1 M
008841
8 ˚C ˚C 7

1 The brake pump pumps oil from the hy- See pressure plate on left Hydraulic oil pump, description page 8
draulic oil tank. frame beam. Section 10 Common hydraulics, group
10.3.1 Tank
1 The brake fluid pump pumps fluid from See pressure plate on left Hydraulic oil pump, description page 8
the brake fluid tank. frame beam. Brake fluid tank, description page 42
2 The brake oil filter cleans the oil. - Brake fluid filter, description page 48
3 The accumulator charging valve directs Max. 0.1 MPa Accumulator charging valve, description
oil to charging of accumulators or page 13
through the brake system's cooling cir-
cuit.
4 The oil cools the wheel brake. - Wheel brake, description page 29
5 The bypass valve in the distribution - Drive axle block, description page 24
block leads oil past the drive axle if the
back pressure through the wheel brake
is too high.

4 Brakes – 4.8 Temperature control, brake fluid cleaning 41

6 The cooler cools the oil. - Oil cooler, description page 44
7 The thermo-bypass valve leads oil past approx. 50 °C Thermal bypass valve, description page 45
the cooler if the temperature is low.
8 The temperature sensor (B762) detects R = 25 kΩ at 20 °C Brake fluid temperature sensor, description
and oil temperature and sends the page 46
frame control unit (D797-1) a voltage D8: Diagnostic menu, see section 8 Control
signal proportional to the oil tempera- system, group 8.4.5.2 HYD, menu 2
ture.
9 The frame control unit (D797-1) trans- Checked by control sys- Section 11 Common electrics, group
mits oil temperature information on the tem, error shown with er- 11.5.3.2 Frame control unit (D797-1)
CAN bus. ror code.
10 When the oil is hot, the frame control U = 24 V with activated Cooling fan, description page 46
unit (D797-1) activates the cooling fan fan D10: Diagnostic menu, see section 8 Control
(M674) and increases airflow through Activates at 65 °C system, group 8.4.5.2 HYD, menu 2
the cooler.
Deactivates at 55 °C
11 If temperature is high, the KID control Checked by control sys- Section 11 Common electrics, group
unit (D795) activates the high brake fluid tem, error shown with er- 11.5.3.12 KID control unit (D795)
temperature warning in the display. ror code.


42 4 Brakes – 4.8.1 Brake fluid tank
4.8.1 Brake fluid tank

Brake fluid tank, description
page
–
The brake fluid tank stores the brake system fluid and is located on the
left side of the machine in front of the fuel tank.
The brake system is separate from other hydraulics and has its own
tank and oil filter. This makes it possible to keep additives out of the
brake system fluid.
Brake fluid is filled directly to the tank. A drain plug is located at the
bottom of the tank. Hatches on top of the tank facilitate internal clean-
ing.
The tank is equipped with a filtered breather that allows volume chang-
es in the tank due to temperature variations and use. See Breather fil-
ter, brake fluid tank, description page 47.
The tank has a sight glass for checking oil level.
007752

4 Brakes – 4.8.2 Tank heater 43
4.8.2 Tank heater

Tank heater, safety
page
–
CAUTION
High voltage.
The tank heater is connected to high voltage (110 -

400 V).
Installation and reconnection of the tank heater may

only be performed by personnel authorized for work
with high voltage.
Tank heater, description

page
–
The brake fluid tank can be equipped with a tank heater, which heats
the brake fluid in the tank and sits in a flange on the front short side of
the tank. The tank heater is designed for cold-climate usage.
The tank heater is operated with high voltage. Heater output is adapt-
ed through different connections and adaptation to different operating
voltage - 110, 230 or 400 V AC. Higher voltage generates higher heat-
er output.
The tank heater is equipped with a programmable thermostat which
007583
maintains the temperature at an even level. The thermostat is fitted di-

rectly onto the heating element and can be adjusted with a knob on the
junction box. Recommended temperature setting is 50 –70 °C.

Hydraulic oil pump, general
page
–
See group 4.3.1 Hydraulic oil pump.

Accumulator charging valve, general
page
–
See 4.3.3 Accumulator charging valve.
4.8.5 Drive axle block

Drive axle block, description
page
–
See Drive axle block, description page 24.
4.8.6 Wheel brake

Wheel brake, general
page
–
See 4.3.9 Wheel brake and drive axle supplier documentation.

44 4 Brakes – 4.8.7 Oil cooler
4.8.7 Oil cooler

page
–
The oil cooler cools the brake system fluid in order to maintain brake
performance. The oil cooler is found inside the side panel on the left
side behind the front wing.
The brake system uses a flow-through cooler with electric cooling fan.
The brake system fluid is cooled when it passes the cooler. Openings
in the frame panel allow air to pass through the cooler.
The cooling fan is screwed onto the cooler. See Cooling fan, descrip-
tion page 46.
009678
Brake system oil cooler, replacement

page
–
NOTE
Safety.

2 Drain the brake fluid tank; see Brake system fluid, changing page
50.
3 Mark up and disconnect hydraulic hoses from the cooler. Let the
oil in the cooler drain into the collection container.
NOTE
contamination.
4 Disconnect the cabling from the cooling fan.
5 Remove the attaching bolts and lift away the cooler.
6 Transfer the cooling fan to the new cooler.
8 Connect the cabling to the cooling fan.
9 Connect the hydraulic hoses to the cooler.

4 Brakes – 4.8.8 Thermal bypass valve 45
NOTE
Check that the O-rings are intact and fitted correctly.
10 Fill the brake fluid tank; see Brake system fluid, changing page
50. The fluid level should be visible in the sight glass.
4.8.8 Thermal bypass valve

Thermal bypass valve, description
page
–
When the oil is cold, the thermo-bypass value guides the oil past the
cooler directly to the tank. The thermo-bypass valve is found inside the
brake fluid tank at the hose connections to and from the cooler.
The thermo-bypass valve is a temperature-regulated bimetal valve
that is open at low temperatures and completely closed at 50 °C.
007754
Thermo-bypass valve, replacement

page
–
NOTE
Safety.

Safety.
50.
4 Remove the thermo-bypass valve found inside the brake fluid
tank.
NOTE
Note how the valve is fitted.
5 Installation is in reverse order.

46 4 Brakes – 4.8.9 Cooling fan
4.8.9 Cooling fan

Cooling fan, description
page
–
The cooling fan (M674) is a suctioning electronic fan. The fan suctions
air from the outside of the machine through the cooler and increases
airflow through the oil cooler as needed. The cooling fan is mounted
inside the cooler inside the side panel behind the left drive wheel.
The cooing fan (M674) is supplied voltage by the frame control unit
(D797-1). The cooling fan is activated when fluid temperature is 65 °C
in the brake fluid tank and is deactivated when fluid temperature is
55 °C.
009678
4.8.10 Sensor brake oil temperature

Brake fluid temperature sensor, description
page
–
The brake fluid temperature sensor (B762) detects the temperature of

the brake system fluid. The sensor is mounted on the rear short side
of the brake fluid tank and therefore takes the accumulated heat in the
brake system fluid into account.
The brake fluid temperature sensor (B762) is supplied voltage by the
frame control unit (D797-1) and sends the control unit a voltage signal
proportional to temperature.
The signal can be checked from the diagnostic menu, see tab 8 Con-
trol system, group 8.4.5.2 HYD, menu 2.
007756

4 Brakes – 4.8.11 Breather filter, brake fluid tank 47
Brake fluid temperature sensor, replacement

page
–
NOTE
Safety.

50.
3 Disconnect the wiring from the fluid temperature sensor.
4 Remove the fluid temperature sensor.
NOTE
5 Connect the cabling to the sensor.
6 Fill the brake fluid tank; see Brake system fluid, changing page
50. The fluid level should be visible in the sight glass.
4.8.11 Breather filter, brake fluid tank

Breather filter, brake fluid tank, description
page
–
The breather filter cleans the air that passes the tank’s breather upon
volume changes arising due to temperature variations and use. The
breather filter is located in a holder on the top of the brake fluid tank.
The breather filter is a paper insert filter. The filter removes moisture
and dust from the air passing through the tank’s breather.
007757

48 4 Brakes – 4.8.12 Brake fluid filter
Breather filter, replacement

page
–
1 Clean the area around the break tank breather filter.

2 Remove the cover from the filter holder.
Remove the centre screw and lift away the cover.
3 Remove the old filter insert.
4 Clean the filter holder.
NOTE
Take care so as not to contaminate the tank.
5 Fit a new filter insert.
1. Brake fluid filler orifice 6 Refit the cover on the filter holder.
2. Breather filter, brake fluid tank

Brake fluid filter, description
page
–
The brake fluid filter eliminates contaminates from the fluid in the brake
system. The filter is secured on a mounting at the side of the brake flu-
id tank.
The brake system fluid filter is a high-pressure filter with removable fil-
ter insert. It is located between the pump and accumulating charging
valve. The fluid is cleaned when it is forced through the glass-fibre ma-
terial of the filter insert before reaching the accumulator charging
valve.
A bypass valve located between the intake and outlet protects the in-
sert. If resistance through the filter surface becomes too great, the by-
pass valve opens a passage past the insert. The bypass function
opens if the oil is viscous (cold or too low/high viscosity) or if the filter
insert is clogged with dirt.
NOTE
When the filter is clogged, the oil is directed past the filter without
cleaning. Therefore, it is very important to replace the filter at the
prescribed interval.
007201

4 Brakes – 4.8.13 Pipes and hoses 49
Brake fluid filter, replacement

page
–
NOTE
Safety.
IMPORTANT
The filter protects the brake system against contami-
nants. It is vital that new contaminants do not enter
the brake system during filter replacement.

Safety.
NOTE
Leave the valve open during replacement.
3 Remove the drain plug on the underside of the filter.
Let the oil run out. Wait a moment since it runs out slowly.
4 Remove the filter holder.
NOTE
The filter holder is heavy. Detach it carefully.
5 Remove the filter insert.
NOTE
Note the location of the O-rings.
6 Clean the filter holder.
7 Fit the O-rings on the filter insert and filter holder. Lubricate the
O-rings with brake fluid.
8 Fit the new filter insert on the filter mounting.
9 Fit the filter holder and drain plug.
11 Start the engine and check the filter holder for leaks.

page
–
4.8.14 Brake system fluid

Brake system fluid, general
page
–

50 4 Brakes – 4.8.14 Brake system fluid
See section F Technical data.
Brake system fluid, changing

page
–
NOTE
Safety.
Safety.
3 Remove the filler cap and drain the brake fluid tank.
4 Remove the drain plug and allow the last of the fluid drain into a
receptacle.
5 Fit the drain plug, using a new gland washer.
6 Fill brake fluid until the fluid level is in the middle of the sight
glass. For volume and grade, see section F Technical data.
7 Fit the filler cap.
1. Brake fluid filler orifice
2. Breather filter, brake fluid tank

5 Steering 1
5 Steering
Table of Contents 5 Steering

mm mm mm mm mm mm
5 Steering........................................................................................................... 3
5.1.2 Mini-wheel .............................................................................................. 3
5.1.3 Joystick .................................................................................................. 4
5.2 Power assisted system ............................................................................... 6
5.2.2 Priority valve ........................................................................................ 13
5.2.3 Steering valve ...................................................................................... 13
5.2.4 Steering cylinder .................................................................................. 15
5.2.5 Steering axle cradle ............................................................................. 16
5.2.6 Link arm ............................................................................................... 17
5.2.7 Wheel spindle ...................................................................................... 17
5.2.8 Wheel hub ............................................................................................ 17
5.2.9 Shuttle valve ........................................................................................ 17
5.2.10 Control valve, mini-wheel/lever steering .............................................. 18
5.2.11 Shuttle valve, mini-wheel/lever steering .............................................. 20
5.2.12 Steering angle sensor .......................................................................... 21
5.2.14 Pipes and hoses .................................................................................. 21
5.2.15 Directional valve, reversible operator’s seat ........................................ 21
5.2.16 Sensor, reversible operator’s seat ....................................................... 22

2 5 Steering

5 Steering – 5 Steering 3
5 Steering
mm mm mm mm mm mm

5.1.2 Mini-wheel
Mini-wheel, description
page
–
3 4
On machines with mini-wheel, the machine is steered with an electric
2 control. A directional valve pressurises the steering cylinder.
The mini-wheel controls are integrated in the left armrest. The controls
1 consist of two rotary potentiometers and three switches to activate the
mini-wheel, select direction of travel and activate the horn.
NOTE
The mini-wheel is deactivated if the standard steering wheel is
used.
Mini-wheel or lever steering can only be activated at speeds be-
low 3 km/h.
Mini-wheel
5 Rotary potentiometers transmit a 0-5 V signal for one revolution. The
potentiometers have phase displacement to determine the direction of
turning. The rotary potentiometers are supplied voltage by the cab
control unit (D790-1) and send it a voltage signal proportional to the
turn to indicate steering deflection.
The relationship between the deflection of the mini-wheel and that of
the wheels can be set to 31 different settings - from linear to extremely
progressive. It is also possible to set how steering deflection is to be
000583
adapted based on machine speed. This is done via the diagnostic

1. Mini-wheel menus; see section 8 Control system, group 8.5.1 Initiation.
2. Travel direction selector (F / N / R) The signals can be read from the diagnostic menu, see section 8 Con-
3. Switch, mini-wheel activation trol system, group 8.4.11.4 EL-STEERING, menu 1.
4. Acoustic signal
5. Armrest Switch, mini-wheel activation
The mini-wheel switch (position 3) activates steering with the mini-
wheel. The switch is supplied voltage by and sends a voltage signal to
the cab control unit (D790-1).
The signals can be read from the diagnostic menu, see section 8 Con-
trol system, group 8.4.11.4 EL-STEERING, menu 2.
Travel direction selector

The travel direction selector is used to choose direction of travel (for-
ward or reverse) when the mini-wheel is activated. The switch is sup-
plied voltage by and sends a voltage signal to the cab control unit
(D790-1).

4 5 Steering – 5.1.3 Joystick
Acoustic signal
The acoustic signal is used to activate the signal horn when the mini-
wheel is activated. The switch is supplied voltage by and sends a volt-
age signal to the cab control unit (D790-1).
5.1.3 Joystick
Joystick, description
page
–
3 4
On machines with joystick, the machine is steered with an electric con-
2
trol. A directional valve actuates the steering cylinder.
The joystick is integrated in the left armrest. The controls consist of a
1 potentiometer and three switches to activate lever steering, select di-
rection of travel and activate the horn.
NOTE
Lever steering is deactivated if the standard steering wheel is
used.
low 3 km/h.
Joystick
5 The sliding potentiometer is supplied voltage by the cab control unit
(D790-1) and sends it a voltage signal proportional to movement to in-
dicate steering deflection.
The relationship between the deflection of the joystick and that of the
wheels can be set to 31 different settings - from linear to extremely
000900

adapted based on machine speed. This is done via the diagnostic
1. Joystick
menus; see section 8 Control system, group 8.5.1 Initiation.
2. Travel direction selector (F / N / R)
3. Switch, joystick activation Joystick position (left, centre, right) can be calibrated with the diagnos-
4. Acoustic signal tic menus; see section 8 Control system, group 8.5.2.2 Calibrate steer-
5. Armrest ing.
Switch, joystick activation

The joystick activation switch switch (position 3) activates steering
with the joystick. The switch is supplied voltage by and sends a voltage
signal to the cab control unit (D790-1).

5 Steering – 5.1.3 Joystick 5
Travel direction selector

The travel direction selector is used to choose direction of travel (for-
ward or reverse) when lever steering is activated. The switch is sup-
plied voltage by and sends a voltage signal to the cab control unit
(D790-1).
Acoustic signal
The acoustic signal is used to activate the signal horn when the lever
steering is activated. The switch is supplied voltage by and sends a
voltage signal to the cab control unit (D790-1).

6 5 Steering – 5.2 Power assisted system
5.2 Power assisted system

Power assisted system, function description
page
–
4
C PP
P CF
LS 3
T LS T
L R
1 C
010733
1 The hydraulic oil pump pumps oil to See pressure plate on left Section 10 Common hydraulics, group 10.4.3
the priority valve. frame beam. Vane pump with fixed displacement
2 The steering wheel is turned and - Steering valve, description page 13

acts on the steering valve's input
shaft.
3 The steering valve pumps pressu- - Steering valve, description page 13

rised oil to the steering cylinder and
transmits a load signal to the main
pumps.
4 The priority valve prioritises pressure See pressure plate on left Priority valve, description page 13
feed to the control valve over working frame beam.
hydraulics.
5 The steering cylinder turns the - Steering cylinder, description page 15

wheels.


5 Steering – 5.2 Power assisted system 7
Power assisted system, reversible operator’s

page
–
seat, function description
D790-1
4 D797-2 D6
P 3 6
PP
C
LS
D5
CF
P T
L R
T LS
8 5 5
1 C
D7
7 7
010732
1 The hydraulic oil pump pumps oil to See pressure plate on left Section 10 Common hydraulics , group 10.4.3
the priority valve. frame beam. Vane pump with fixed displacement
2 The steering wheel is turned and - Section 9 Frame, body, cab and accessories ,
acts on the steering valve's input group 9.1 Controls and instruments
shaft.
3 The steering valve pumps pressu- - Steering valve, description page 13

rised oil to the steering cylinder and
transmits a load signal to the main
pumps.
4 The priority valve prioritises pres- See pressure plate on left Priority valve, description page 13
sure feed to the control valve over frame beam.
working hydraulics.
5 Either the reversible operator’s seat U = 24 V Reversible operator’s seat sensor, description
forward sensor (S720-F) or the re- page 22
versible operator’s seat rearward D5: Diagnostic menu, see section 8 Control
sensor (S720-R) sends a voltage system, group 8.4.11.1 VBFS, menu 3
signal to the frame option control unit
(D797-2) depending on which way
the operator’s seat faces.


6 The frame option control unit (D797- U = 24 V Directional valve, reversible operator’s seat,
2) supplies voltage to either the description page 21
steering forward solenoid valve D6: Diagnostic menu, see section 8 Control
(Y636-1) or the steering rearward system, group 8.4.11.1 VBFS, menu 5
solenoid valve (Y636-2).
7 The steering forward solenoid valve - Directional valve, reversible operator’s seat,
(Y636-1), or steering rearward sole- description page 21
noid valve (Y636-2) pressurises the D7: Diagnostic menu, see section 8 Control
valve spool in directional valve, re- system, group 8.4.11.1 VBFS, menu 5
versible operator’s seat.
8 Directional valve, reversible opera- - Directional valve, reversible operator’s seat,

tor’s seat, controls pressure to the description page 21
steering cylinder.

wheels.


Lever steering/mini-wheel, function description

page
–
Mini-wheel or lever steering is a steering option that makes it possible

to steer the machine with an electric control.
The relationship between the deflection of the control and that of the
wheels can be set to 31 different settings - from linear to extremely
adapted based on machine speed. This is done via the initiation men-
us; see section 8 Control system, group 8.5.1 Initiation.
NOTE
The mini-wheel/lever steering is deactivated if the standard steer-
ing wheel is used.
low 3 km/h.

Lever steering ac- Voltage signal from mini-wheel/lever Section 9 Frame, body, cab and accessories
tivated steering switch.
Steering wheel No signal from steering angle sensor Steering angle sensor, description page 21
stationary
Speed Below 2 km/h (at engagement) Section 2 Transmission
Emergency stop Not activated Section 11 Common electrics, group 11.5.1.4 Emergency
switch stop switch voltage

10
D11 D2
2
12 3
D790-2 D790-1
11 D797-2
4
D4 5 D4
8
C PP
P
LS
P CF P
TP
6, 7
LS
T1
T LS A B
T
C L R
010731
1 The hydraulic oil pump pumps oil See pressure plate on left Section 10 Common hydraulics, group 10.4.3
from the hydraulic oil tank. frame beam. Vane pump with fixed displacement
2 The joystick switch or mini-wheel Signal 1, U = 0.5 - 4.5 V Section 9 Frame, body, cab and accessories
switch sends a voltage signal to the Signal 2, U = 0.5 - 4.5 V D2: Diagnostic menu, see section 8 Control
cab control unit (D790-1). (mini-wheel only) system, group 8.4.11.2 EL-STEERING, menu 1
3 The cab control unit (D790-1) trans- Checked by control sys- Section 11 Common electrics, group 11.5.3.1
mits the desired steering deflection tem; error indicated with Cab control unit (D790-1)
on the CAN bus. error code.
4 The frame option control unit (D797- - Control valve for lever steering or mini-wheel,
2) supplies voltage to the solenoid description page 18
valve for steering right (Y636-3) or D4: Diagnostic menu, see section 8 Control
the solenoid valve for steering left system , group 8.4.11.2 EL-STEERING, menu
(Y636-4). 4 and 8.4.11.2, menu 5
5 The solenoid valve, steering right - Control valve for lever steering or mini-wheel,
(Y636-3) or solenoid valve, steering description page 18
left (Y636-4) pressurises the steer-
ing spool in the solenoid valve for le-
ver steering or mini-wheel.
On machines with reversible opera-

tor’s seat, right is changed to left
when the operator’s seat is turned to
the back.


6 The steering spool changes position - Control valve for lever steering or mini-wheel,
and pressurises the steering cylin- description page 18
der.
7 The solenoid valve for lever control - Control valve for lever steering or mini-wheel,
or mini-wheel sends a load signal to description page 18
the priority valve.
8 The priority valve prioritises pres- See pressure plate on left Priority valve, description page 13
sure feed to the control valve over frame beam.
working hydraulics.

wheels. Link arm, description page 17
Wheel spindle, general page 17
10 The steering wheel is turned and - Section 9 Frame, body, cab and accessories,
acts on the steering valve's input group 9.1 Controls and instruments
shaft.
11 The steering angle sensor (B770) U = 24 V Steering angle sensor, description page 21
sends a voltage signal to the KIT cab D11: Diagnostic menu, see section 8 Control
control unit (D790-2). system, group 8.4.11.2 EL-STEERING, menu 3
12 The KIT cab control unit (D790-2) Checked by control sys- Section 11 Common electrics, group 11.5.3.11
transmits an interrupt steering re- tem; error indicated with KIT control unit (D790-2)
quest on the CAN bus. error code.


12 5 Steering – 5.2.1 Hydraulic oil pump

Hydraulic oil pump, description
page
–
Steering is fed oil from the hydraulic pump for steering and load han-
dling; see section 10 Common hydraulics, group 10.4.3 Vane pump
with fixed displacement.
Steering pressure, checking

page
–
NOTE
Safety.
1 Operate and warm up the machine so that the hydraulic oil reach-
es operating temperature, at least 50 °C.
3 Connect the pressure gauge (0- 25 MPa) to the steering pressure
measuring outlet on the priority valve; see section 10 Common
hydraulics, 10.5.2 Priority valve.
4 Start the engine and increase engine speed to approx. 1200 rpm.
010730

5 Steering – 5.2.2 Priority valve 13
5 Turn the steering wheel fully and read pump pressure during
steering wheel movement. Compare this to the steering pressure
on the hydraulics plate. The max. pressure measured on the
MPa
pump should be 1.5 MPa more than the steering pressure on the
pressure plate.
MPa
MPa er.
MPa 8 Remove the pressure gauge and fit the protective cap on the
measuring outlet.
MPa MPa MPa MPa
007734
5.2.2 Priority valve

Priority valve, description
page
–
See section 10 Common hydraulics , group 10.5.2 Priority valve.
5.2.3 Steering valve

Steering valve, description
page
–
The steering valve is a progressive, closed centre, non-reaction valve

with load signal connection to the priority valve.
The load signal generates load-dependent control of oil flow from the
1 priority valve to the steering valve. Closed centre means that the steer-
ing valve is closed in its neutral position. This is necessary so that sig-
nal pressure can be connected to the steering valve.
2
5 The steering valve consists of a gear pump and a distribution valve.
When the steering wheel is turned, oil flows from the main pump over
4 3
the gear pump to the distribution valve, which guides oil to the steering
cylinder. The gear pump ensures that the oil flow fed to the cylinder is
proportional to the steering wheel angle.
There are double shock and anti-cavitation valves in the steering
valve. The shock valves protect the hydraulics against pressure spikes
which can arise from impacts on the steering wheels. The anti-cavita-
tion valves (non-return valves) protect against vacuum on the piston’s
rear side, which can lead to cavitation.
007731
1. Pressure to steering cylinder (R)

2. Load signal to priority valve (LS)
3. Pressure to steering cylinder (L)
4. Feed pressure from priority valve (P)
5. Tank return (T)

14 5 Steering – 5.2.3 Steering valve
Steering valve, replacement

page
–
NOTE
Safety.
2 Depressurize the hydraulic systems, See section B Safety.
3 Detach the steering valve from the brake pedal.
Remove the steering valve attaching bolts and lower the steering
valve.
4 Mark up and detach the hydraulic hoses from the steering valve.
NOTE
5 Remove the steering valve.
6 Transfer the connection adapters to the new steering valve.
NOTE
Transfer one at a time so that the marking is not mixed up.
7 Connect the hydraulic hoses to the steering valve in accordance
with the marking.
NOTE
8 Connect the new steering valve to the brake pedal.
Place the steering valve and check that the steering wheel shaft’s
splines enter straight in the steering valve’s slot. Install the at-
taching bolts.
10 Check that the connections on the steering valve are sealed.
11 Steer very carefully a few times right - left, to bleed the steering
valve and steering cylinder.

5 Steering – 5.2.4 Steering cylinder 15
5.2.4 Steering cylinder

Steering cylinder, description
page
–
The steering cylinder acts on the wheels via the link arms. The steer-
1 2 3 5 4 6 7 8
ing cylinder is a double-acting hydraulic cylinder.
007732
1. Wheel hub
2. Wheel spindle
3. Link arm
4. Steering axle cradle
5. Front suspension
6. Steering cylinder
7. Rear suspension
8. Counterweight
Steering cylinder, replacement

page
–
NOTE
Safety.
1 Park the machine with the wheels fully turned so that the steering
cylinder can be lifted out to one side.
Safety.
4 Disconnect the link arms from the steering cylinder.
5 Mark up and disconnect the hydraulic hoses from the steering
cylinder.
NOTE
1. Link arm attachment

2. Hydraulic connection

16 5 Steering – 5.2.5 Steering axle cradle
6 Remove the steering cylinder’s attaching bolts.

7 Change the steering cylinder. Lift aside the steering cylinder.
NOTE
The steering cylinder is heavy, use lifting equipment.
8 Support the new steering cylinder so that the holes in the attach-
ing bolts are lined up directly opposite the holes in the steering
axle.
9 Lubricate and fit the steering cylinder retaining screws. Tighten
the screws crosswise a few times with increasing torque until you
reach 680 Nm (oiled screw).
Attaching bolts steering cylinder. 10 Transfer parts to the new steering cylinder.
NOTE
11 Fit the link arms to the steering cylinder.
12 Connect the hydraulic hoses to the steering cylinder.
NOTE
13 Close the drain valve on the accumulator charging valve. See
section B Safety.
1. Link arm attachment

2. Hydraulic connection
Hydraulic cylinders, repairs

page
–
See section 10 Common hydraulics, group 10.7.1 Hydraulic cylinders.
5.2.5 Steering axle cradle

Steering axle cradle, general
page
–
See section 6 Suspension, group 6.2.1 Steering axle cradle.

5 Steering – 5.2.6 Link arm 17
5.2.6 Link arm

Link arm, description
page
–
The link arm transfers the lateral movement of the steering cylinder to
1 2 3 5 4 6 7 8
turning the wheel spindles.
The setting of the steering wheels cannot be adjusted. If the link arms
are deformed in a way that changes the setting of the steering wheels,
they must be replaced.
The link arms must be turned to the right direction, otherwise they can
be damaged by the rims with large wheel angles.
007732
1. Wheel hub
2. Wheel spindle
3. Link arm
5. Front suspension
7. Rear suspension
8. Counterweight
5.2.7 Wheel spindle

Wheel spindle, general
page
–
See section 6 Suspension, group 6.2.2 Wheel spindle.
5.2.8 Wheel hub

Wheel hub, general
page
–
See section 6 Suspension, group 6.2.3 Wheel hub.
5.2.9 Shuttle valve

Shuttle valve, general
page
–
See section 10 Common hydraulics, group 10.5.3 Shuttle valve.

18 5 Steering – 5.2.10 Control valve, mini-wheel/lever steering
5.2.10 Control valve, mini-wheel/lever

steering
Control valve for lever steering or mini-wheel,
page
–
description
1
On machines with lever steering or mini-wheel, steering cylinder dis-
2 placement is regulated by the control valve for lever steering or mini-
wheel. The control valve is located on the inside of the right frame
beam in front of the engine. The control valve is regulated by the frame
option control unit (D797-2).
6
The control valve is an electrohydraulically controlled, proportional
3
and pressure-compensated directional valve. Electrically controlled
pressure reducing valves convert electrical current to servo pressure.
4
The servo pressure controls the spring-centred valve spools, which
control pressure and flow for the function in question. The valve spools
5 have flow limits so that several functions can be activated simultane-
ously.
Valve slide, steering

The valve slide controls the direction and steering angle by controlling
007733
the hydraulic pressure to the steering cylinder.

The valve slide is controlled by servo valve right and servo valve left.
1. Load signal (LS)
2. Pressure feed (P) Servo valve right
3. Tank return (T) Servo valve right controls servo pressure to valve slide, steering, so
4. Steering cylinder connection (B) that it controls oil pressure for steering right.
5. Tank return (TP)
Servo valve right regulates electrically with the solenoid valve steering
6. Steering cylinder connection (A)
right (Y636-3), which is activated by the frame option control unit
(D797-2).
The signals can be read with the diagnostic menu; see menu 8 Control
system, group 8.4.11.2 EL-STEERING, menu 5.
Servo valve left

Servo valve left controls servo pressure to valve slide, steering, so that
it controls oil pressure for steering left.
Servo valve left regulates electrically with the solenoid valve steering
left (Y636-4), which is activated by the frame option control unit (D797-
2).
The signals can be read with the diagnostic menu; see section 8 Con-

5 Steering – 5.2.10 Control valve, mini-wheel/lever steering 19
Control valve for lever steering or mini-wheel,

page
–
replacement
NOTE
Safety.
Safety.
1 3 Mark up and detach the hydraulic hoses from the control valve.
NOTE
2
Plug all connections immediately to protect the hydraulic
system from impurities.
4 Mark up and detach the wiring from the control valve.
6
5 Remove the control valve.
3
Remove the attaching bolts and lift away the valve. Place the
4 valve on a clean and protected surface.
6 Transfer parts to the new control valve.
5
NOTE
Check that the O-rings on the hydraulic connections are in-
tact and in place.
NOTE
007733
Transfer one adapter component at a time so that the mark-

1. Load signal (LS) ing is not mixed up.
2. Pressure feed (P)
7 Mark up the servo valves on the new control valve.
3. Tank return (T)
4. Steering cylinder connection (B) 8 Fit the valve.
5. Tank return (TP) 9 Connect the wiring to the control valve in accordance with the
6. Steering cylinder connection (A) marking.
10 Connect the hydraulic hoses to the control valve in accordance
with the marking.
NOTE

20 5 Steering – 5.2.11 Shuttle valve, mini-wheel/lever steering
12 Check the function.
CAUTION
Air in the hydraulic system may cavitate and result in
product damage.
Activate the steering carefully and drive a couple of

times with lowest possible speed to avoid cavitation.
13 Check the oil level in the hydraulic oil tank with the lift cylinders
completely down and the extension cylinder completely in. The
oil level should be in the top of the level glass. Top up as needed.
CAUTION
Overfilling of oil, leakage, and environmental damage.
The hydraulic oil level is checked with the boom com-

pletely lowered and retracted.
5.2.11 Shuttle valve, mini-wheel/lever

steering
Shuttle valve for mini-wheel or lever control,
page
–
description
Machines with lever steering or mini-wheel have an extra shuttle valve

for the control signal cables of the hydraulic oil pumps. The frame op-
tion shuttle valve is located on the LS connection bracket on the frame
option control valve.
The shuttle valve forwards the control signal from the control valve to
the main pumps.
009631
Shuttle valve, frame option

5 Steering – 5.2.12 Steering angle sensor 21
5.2.12 Steering angle sensor

Steering angle sensor, description
page
–
1
2
The steering angle sensor (B770) detects if the steering wheel is
turned and sends a signal to the KIT control unit (D790-2). This is used
to disengage lever steering or the mini-wheel. The sensor is located
by the steering shaft inside the panels.
The sensor is tripped by an activator on the steering shaft with four
lobes. The location of the sensor and lobes’ spacing means that small
steering wheel movements can be detected.
The signals can be read with the diagnostic menu; see section 8 Con-
002628

Pipes and hoses, description
page
–
5.2.15 Directional valve, reversible

operator’s seat
Directional valve, reversible operator’s seat,
page
–
description
Machines with a reversible operator’s seat have an additional direc-

tional valve (reversing valve) between the steering valve and steering
cylinder. The directional valve shifts the connection between the steer-
ing valve and the steering cylinder when the operator’s seat is turned
1 2 round for driving in reverse so that steering wheel and wheel move-
ments correspond.
The directional valve is actuated by the steering forward solenoid
valve (Y636-1) or the steering rearward solenoid valve (Y636-2),
which is activated by the frame option control unit (D797-2).
The signals can be read from the diagnostic menu; see section 8 Con-
trol system, group 8.4.11.1 VBFS, menu 5.
See also section 9 Frame, body, cab and accessories, group 9.3.10
Reversible operator’s seat.
002617
6 5 4 3
1. Pressure from control valve (A)
2. Pressure from control valve (B)
3. Solenoid valve for steering forward (Y636-1)
4. Pressure to steering cylinder (P)
5. Pressure to steering cylinder (T)
6. Solenoid valve, steering rearward (Y636-2)

22 5 Steering – 5.2.16 Sensor, reversible operator’s seat
5.2.16 Sensor, reversible operator’s seat

Reversible operator’s seat sensor, description
page
–
Machines with a reversible operator’s seat have two NO (normally

open) switches that detect whether the operator’s seat is facing for-
ward or rearward.
The forward reversible operator’s seat sensor (S720-F) and the rear-
1 ward reversible operator’s seat sensor (S720-R) send a voltage signal
to the frame option control unit (D797-2). This regulates the reversible
operator’s seat directional valve.
The signals can be read from the diagnostic menu; see section 8 Con-
002629
trol system, group 8.4.11.1 VBFS, menu 3.
2
See also section 9 Frame, body, cab and accessories , group 9.3.10
1. Rearward reversible operator’s seat sensor (S720-
Reversible operator’s seat.
R)
2. Forward reversible operator’s seat sensor (S720-F)

6 Suspension 1
6 Suspension
Table of Contents 6 Suspension

mm mm mm mm mm mm
6 Suspension..................................................................................................... 3
6.2 Suspension ................................................................................................. 3
6.2.1 Steering axle cradle ............................................................................... 4
6.2.2 Wheel spindle ........................................................................................ 7
6.2.3 Wheel hub ............................................................................................ 14
6.3 Tyres and rims .......................................................................................... 19
6.3.1 Tyres .................................................................................................... 20
6.3.2 Rims ..................................................................................................... 22
6.3.3 Nut, washer and clamp ........................................................................ 23

2 6 Suspension

6 Suspension – 6 Suspension 3
6 Suspension
mm mm mm mm mm mm
6.2 Suspension
Bushing steering axle mounting, changing
page
–
DANGER
Steering axle and machine are very heavy.
It is not permissible to go under a machine which has

been lifted by a jack or similar. For machine weights,

er.
3 Remove the counterweights on the rear of the machine.
NOTE
Mark the locations of the counterweights so that they can be
refitted at the same spot. This is important for the machine’s
stability.
4 Support under the steering axle so that it cannot fall over.
5 Connect lifting equipment to the rear of the machine and take up
the slack so that the steering axle’s mounts are relieved.
NOTE
Do not lift so much that the wheels are off the ground.
6 Remove the shafts holding the steering axle.
8 Support the machine under the frame.
9 Move the steering axle so that the mountings can be accessed.
NOTE
If needed, disconnect the cabling for the sensors on the
steering axle.
010564
The illustration shows front mounting

4 6 Suspension – 6.2.1 Steering axle cradle
10 Remove the washers that hold the bushing in place.

2 11 Press out the bushing.
1 12 Clean the bearing surfaces on the steering axle.

13 Press in the new bushing. Grease the bushing to facilitate instal-
lation.
14 Install the washers that hold the bushing in place.
15 Move the steering axle into place under the frame.
16 Grease and install the pins by the steering axle’s mounts.
3
17 Fit the counterweights.
4
010121
NOTE
1. Steering axle mounting Make sure that all counterweights are refitted and that they
2. Rubber bushing are fitted in the exact same location as before. The stability
3. Washers of the machine is affected if the counterweights are
4. Bolt changed.
6.2.1 Steering axle cradle

Steering axle cradle, description
page
–
The steering axle is pendulum suspended with a double-acting steer-

1 2 3 5 4 6 7 8
ing cylinder. The construction comprises a minimum of moving parts
to minimise service points and simplify maintenance.
The chassis suspension comprises maintenance-free parts. The rear
suspension is designed with a fixed bolted joint.
007732
1. Wheel hub
2. Wheel spindle
3. Link arm
5. Front suspension
7. Rear suspension
8. Counterweight

6 Suspension – 6.2.1 Steering axle cradle 5
Steering axle cradle, replacement

page
–
DANGER
Steering axle and machine are very heavy.
Under no circumstances go under a machine which

has been lifted by a jack etc. For machine weights,
1 Clean the steering axle and its surrounding area.

er.
5 Remove the counterweights on the rear of the machine.
NOTE
Mark the locations of the counterweights so that they can be
refitted at the same spot. This is important for the machine’s
stability.
6 Connect the lifting equipment to the rear section of the machine.
7 Tension the lifting equipment, do not lift so high that the wheels
start to hang.
8 Support the rear of the machine.
9 Detach the hydraulic hoses from the steering cylinder.
NOTE
contamination.
10 Remove the shafts holding the steering axle.
12 Lift out the steering axle.
CAUTION
The steering axle may start to roll.
Crushing injury!
Make sure that the steering axle does not start uncon-
trolled movement.

6 6 Suspension – 6.2.1 Steering axle cradle
13 Adjust the support so that the machine is secured in the new po-
sition.
14 Lift the steering axle into place underneath the frame.
15 Remove the support under the frame.
16 Lower the rear of the machine.
17 Fit the shafts at the steering axle mountings.
18 Connect the hydraulic hoses to the steering cylinder.
NOTE
Check that the O-rings are intact and that they are fitted cor-
rectly.
19 Remove the lifting equipment from the machine.
20 Fit the counterweights.
NOTE
Make sure that all counterweights are refitted and that they
are fitted in the exact same location as before. The stability
of the machine is affected if the counterweights are
changed.

6 Suspension – 6.2.2 Wheel spindle 7
6.2.2 Wheel spindle

Wheel spindle, description
page
–
The wheel spindle is the link between steering axle and wheel hubs
1 2
3 which means that the wheels can be turned.
4 1 2 3 4 5 6
5
6
7
8 7
6
9
5
4
1 10 5 8
11
010115
007737
DCF 280-330
DCF 370-500
1. Cover 7. Wheel spindle
1. Wheel spindle 5. Spindle bolt bearing
2. Castle nut 8. Spindle bolt
2. Spindle bolt 6. Thrust bearing
3. Lock plate 9. Spacer ring 3. Seal 7. Thrust washer
4. Washer 10. Nut 4. Cover 8. Lock screw
5. Bearing 11. Split pin
6. Seal ring

8 6 Suspension – 6.2.2 Wheel spindle
Spindle bolt bearing, replacement (DCF 280-330)

page
–
1 Clean the wheel spindle and its surrounding area.

2 Lift the machine under the steering axle at the wheel in question.
Support the steering axle in a suitable way.
3 Remove the steering wheel in question.
4 Detach the link arm from the wheel spindle.

1
Remove the lock screw and then remove the axle. Move the link
2
3 arm aside.
5 Position a lifting strap inside the hub to secure the spindle.
4
5 6 Remove the cover (position 1) from the upper bearing of the spin-
dle bolt.
6 7 Move aside the lock plate tabs (position 3). Slacken the castle nut
7 (position 2) and remove the lock plate and washer (position 3 and
4).
8 Remove the guard (position 1) that protects the lower bearing.
8 Remove the split pin (position 11) that locks the nut and remove
the nut (position 10). The bearing’s inner race is now detached
and can be removed.
9 Remove the spindle bolt (position 6) by tapping it upward. The
12 9
5 upper bearing’s inner race then follows with the spindle bolt.
4 10 Lift away the steering swivel (position 8) using a lifting device.
007739
10
1 11 11 Remove the seal rings (position 7) from the steering axle cradle
(position 12).
1. Guard 7. Seal ring 12 Remove the outer bearing races from the steering axle cradle us-
2. Castle nut 8. Steering swivel ing a suitable puller.
3. Lock plate 9. Spacer ring

NOTE
4. Washer 10. Nut If you do not have a suitable puller, eyes can be welded to the in-
ner bearing race in order to pull the races out. The bearing races
5. Bearing 11. Split pin
shrink after welding, making them easier to remove.
6. Spindle bolt 12. Steering axle cra-
13 Thoroughly grease the outer bearing races with EP2 universal
dle
grease. Press the bearing races into the steering axle cradle.
NOTE
These are tapered bearings. Fit the inner bearing race so that the
larger internal diameter faces out.

A round bearing must be made for each bearing size and used
when pressing the bearing races in. A heavy hammer can then
be used to drive in the bearing race. Do not tap the bearing race
directly since there is then a great risk that the race will overturn
and become stuck in the bearing cup.
14 Fit new seal rings (position 7) in the steering axle cradle, using a
ring with a suitable dimension (e.g. a socket) to tap the seal rings
into place. The seal rings will be damaged if you tap on them di-
rectly with a hammer.
15 Lift the steering spindle (position 8) into place using a lifting
device.
16 Fit the spindle bolt (position 6), the spacer ring (position 9) and
the lower bearing’s race (well greased with EP2 universal
grease). Position the nut (position 10).
17 Tighten the nut (position 10) to its full tightening torque 700 Nm
±200 Nm (oiled screw) and lock it with a new split pin (position
11).
18 Fit the upper bearing’s inner race (well greased with EP2 univer-
sal grease), the washer and a new lock plate (position 4 and 3).
Lubricate the lock plate with EP2 universal grease to ensure that
it is not damaged when the castle nut (position 2) is tightened.
19 Fill both bearings with EP2 universal grease and check that they
run free.
20 Tighten the castle nut (position 2) to full tightening torque
1000 Nm ±100 Nm (oiled screw) . Slacken the lifting strap
around the steering spindle while tightening the castle nut so that
it does not prevent the nut from attaining the right tightening
torque.
21 Check that the wheel spindle can be rotated and that resistance
is uniform.
22 Coat the contact surfaces of the guard (position 1) with sealant,
fill the guard with EP2 universal grease and fill with grease
through the lubricating nipples when the guard is in place and the
sealant has hardened.
23 Connect the link arm to the wheel spindle.
Lubricate the link arm bearings with EP2 universal grease.
24 Fit the wheel.
25 Remove the support and lower the steering wheel.
26 Test-run the machine and test the steering. Check also that the
machine feels stable when driving straight ahead.

Spindle bolt bearing, replacement (DCF 370-500)

page
–
1 Clean the wheel spindle and its surrounding area.

2 Lift the machine under the steering axle at the wheel in question.
Support the steering axle in a suitable way.
4 Detach the link arm from the wheel spindle.

2
Remove the lock screw and then remove the axle. Move the link
arm aside.
1 5 Position a lifting strap inside the hub to secure the spindle.
6 Remove the covers at the spindle bolt’s upper and lower bearing.
7 Remove the grease between the cover and spindle bolt.
004516
1. Axle link arm

2. Cover (upper)
3. Cover (lower)
8 Remove the spindle bolt’s upper and lower lock screw.
Remove the nut and the lock screw.
9 Adjust the lifting equipment to relieve the load on the wheel spin-
dle.
10 Remove the spindle bolt.

Pull the spindle bolt up, using a sliding hammer or the like con-
nected to the threaded hole in the centre of the spindle bolt.
11 Remove the wheel spindle.
Place the wheel spindle on a soft surface.

12 Remove the thrust bearings from the steering axle.

1
13 Replace the bearing races in the steering axle.
Press out the old bearing races with a drift.
14 Clean the surfaces inside the steering axle.
15 Press in the new bearing races with a drift.
Thoroughly coat the bearing races with grease.
NOTE
The upper bearing race must jut out so that it is level with the
thrust bearing slotted washer.
004517
16 Fit new thrust bearings in the steering axle. The treated side must
face the wheel spindle. Fit the screws as illustrated.
1. Thrust bearing Thoroughly coat the bearing races with grease. For grade, see
section F Technical data.
IMPORTANT
Fit only the inner retaining bolts, otherwise the wheel
spindle cannot be lifted into place. Only tighten the
bolts loosely so that the thrust bearings can be accu-
rately secured.
17 Place new O-rings on the wheel spindle.

Pull the O-ring toward the hub.
18 Place new thrust washers on the wheel spindle.
Coat both sides of the thrust washers with lubricating grease and
position the bearing in the wheel spindle. Note the position of the
thrust washer so that the guide pin fits into the recess in the bear-
ing.
19 Lift the wheel spindle into place on the steering axle.

20 Fit the spindle bolt.

Coat the spindle bolt with lubricating grease and press it into
place.
NOTE
Check that the spindle bolt is turned so that the holes for the
guide screws align with the holes in the wheel spindle. It is
important that the spindle bolt is perfectly seated before the
lock screws are fitted. It is not possible to "tighten" the spin-
dle bolt into place.
21 Fit the lock screws and lock with lock nuts. Tighten to 250 Nm
(oiled screw).
22 Coat the space between the wheel spindle and steering axle with
lubricating grease.
23 Position the O-rings.
24 Fit the remaining retaining screws to the thrust bearings as illus-

1
trated. Tighten to 25 Nm (oiled screw).
004517
1. Thrust bearing

25 Fit the upper cover and the lower cover.

2
26 Lubricate the upper and lower bearings of the spindle bolt with lu-
bricating grease.
1 27 Rock the wheel spindle back and forth a few times to even out the
grease. Check that resistance is uniform.
28 Connect the link arm to the wheel spindle.
Lubricate the link arm bearings with grease.
29 Fit the wheel.
004516
3 31 Test-run the machine and test the steering. Check also that the
machine feels stable when driving straight ahead.
1. Axle link arm
2. Cover (upper)
3. Cover (lower)

14 6 Suspension – 6.2.3 Wheel hub
6.2.3 Wheel hub

Wheel hub, description
page
–
The wheel hub holds the wheel in place and allows the wheel to rotate.
1 2 3 4 5 6
007736
1. Hub nut with lock washer

2. Outer wheel bearing
3. Hub
4. Inner wheel bearing
5. Seal
6. Thrust ring

6 Suspension – 6.2.3 Wheel hub 15
Wheel bearing, replacement

page
–
1 Lift the machine under the steering axle by the wheel in question.
Support securely under the steering axle.
3 Clean the hub cover and its surrounding area.

4 Remove the hub cover.
5 Wipe away grease from hub cover and hub nuts. Handle it as en-
vironmentally hazardous waste.
6 Secure the hub with a lifting strap.

Route the lift sling over the hub and around a wheel bolt. Install a
clamp and nut to secure the lift sling. Use manual forklift, pallet
forks or similar to lift the hub.
7 Bend up the lock washer’s tabs, remove the lock nut and the lock
washer.
8 Tension the lifting equipment so that the hub is unloaded.
9 Remove the hub nut.

10 Lift out the hub from the spindle.

Remove the outer bearing inner race and pull the hub from the
axle.
11 Remove the inner bearing from the wheel spindle.
12 Remove the seal from the hub.

13 Remove the bearings’ outer races from the hub.
Use a drift and press out the bearing races.
14 Clean the hub and smear the inside with lubricating grease.
15 Fit new bearing races in the hub.
Use a drift and press in the bearing races. Never tap directly on
the bearings.
NOTE
Fit the outer bearings with the larger diameter outward.
16 Fit a new seal on the inside with the seal lip turned out.
Press in a new seal in the hub. Use a suitable round plate, the
seal does not tolerate impacts from a hammer.
NOTE
Turn the seal correctly.

6 Suspension – 6.2.3 Wheel hub 17
17 Install the inner bearing’s inner race and rollers on the wheel
spindle. Pack the bearing with lubricating grease.
18 Fill the cavity in the hub with lubricating grease.
19 Fit the hub on the wheel spindle.
20 Install the outer bearing, protecting washer, and bearing nut.

Pack in the bearing with grease and fit the bearing.
Fit the washer and hub nut with the smooth surface in towards the
hub.
21 Remove the lifting equipment.

22 Torque the bearing nut as follows.

A. Lubricate the thread and the side of the nut facing the bear-
ing with oil (SAE 80W7140).
B. Tighten the nut to 250 Nm (oiled screw).
C. Rotate the hub 10 revolutions.
D. Angle tighten the nut 45 °.
E. Rotate the hub 10 revolutions.
F. Angle tighten the nut 45 °.
23 Grease the lock washer and fit it.
24 Fit the lock nut and tighten to at least 250 Nm (oiled screw) or
as hard as necessary to engage the locking washer in the closest
groove. Lock the bearing nut and lock nut with the locking wash-
er.
25 Fill the bearing casing with grease and fit it.

26 Grease the wheel bearing with grease through the grease nipple.
Lift the seal ring’s lip with a small screwdriver to facilitate the es-
cape of air. Grease until grease comes out at the seal.
27 Fit the wheel.

6 Suspension – 6.3 Tyres and rims 19
6.3 Tyres and rims

Tyres and rims, safety
page
–
DANGER
Always block the wheels on the side of the axle that is
not going to be worked on before positioning the jack.
Always secure the jack to prevent it from sliding out
of position.
Deflate the tyre before removal. Otherwise the conical

ring and locking clips can loosen and shoot out when
the pressure is changed. With double wheel fitting
both tyres must be deflated!
Do not release air through the valve if the tyre or rim

is damaged. Drill a hole in the tread to release the air.
Damaged tyres may explode.
Never stand directly in front of the wheel when deflat-

ing or inflating. The conical ring and locking clips can
loosen and shoot out when the pressure is changed.
Never install damaged tyres or rims.
It's prohibited to repair rims with welding.
It's prohibited to operate the machine if one of the

tyres is flat.
Wheels, tyres and rims are dimensioned and selected

for each machine type so that maximal wheel loads
and travel speeds are not exceeded. That is why it is
forbidden to change tyre dimension, tyre brand, tyre
type, rim type or rim brand without approval from
Kalmar Industries AB.

20 6 Suspension – 6.3.1 Tyres
CAUTION
When removing wheels, the wheel nuts should be left
in place after loosening. If the wheel nuts are removed
immediately, the wheel may release from the hub.
When removing drive wheels, make sure that the

wheels are secured in position when the spacer rings
are removed. If the wheels move they may displace
the spacer rings, with crushing injuries as a result.
When installing drive wheels, ensure that the clamps

clamp straight on the spacer ring.
Wheel nuts should be check-tightened after 4-5 oper-

ating hours.
Always follow the tyre manufacturer’s or other ap-

proved instructions when changing tyres.
Never use a steel hammer to install or remove rim

components. Instead, use a lead, brass or plastic mal-
let.
Keep the tyre pressure at the prescribed level. Insuf-

ficient tyre pressure impairs stability and reduces the
machine’s capacity.
Remove penetrating objects, such as crushed glass,

pieces of wood and metal filings.
Check if tyre wear is abnormal. This could indicate a

mechanical fault. Rectify faults immediately and
change damaged tyres.
6.3.1 Tyres
Tyres, description
page
–
The tyres are the point of contact between the machine and the
ground. These absorb unevenness and provide suspension.
The drive axle is subject to major forces during operation. If each tyre’s
rolling circumference differs, the stresses on the drive axle increase.
For this reason it is important that the tyres on the drive axle have
equal wear and correct air pressure.
Spare and exchange tyres shall be of a make approved by Kalmar In-
dustries.
002027
Front wheels

6 Suspension – 6.3.1 Tyres 21
002026
Rear wheels
Tyre replacement
page
–
DANGER
Changing tyres is complicated and dangerous work.
FATAL DANGER!
Leave tyre work to authorised personnel/ tyre compa-

ny.
The rims must be checked when tyres are changed. See Maintenance
manual DCF 280-500.

22 6 Suspension – 6.3.2 Rims
6.3.2 Rims
Rim, description
page
–
The rim is split to make it possible to fit a tyre, the rim consists of the
1 2 3 4 5 6 following parts.
• Rims
• Rim bead seat
• Rim flange
• Lock ring
• Lock lugs
• Hub plate
7
007735
1. Lock ring
2. Rim flange
3. Tapered rim bead seat
4. O-ring
5. Rim
6. Rim flange
7. Wheel nut
8. Wheel clamp

6 Suspension – 6.3.3 Nut, washer and clamp 23
6.3.3 Nut, washer and clamp

Nut, washer and clamp, description
page
–
The rim is attached to the wheel hub with nuts and clamps.
1 2 3 4 5 6
The number of nuts and clamps varies depending on the type of drive
axle and steering axle used.
7
007735
1. Lock ring
2. Rim flange
3. Tapered rim bead seat
4. O-ring
5. Rim
6. Rim flange
7. Wheel nut
8. Wheel clamp

24 6 Suspension – 6.3.3 Nut, washer and clamp
Wheel bolt, replacing

page
–

2 Raise the machine with a jack positioned under the steering axle.
3 Remove the steering wheel; see Maintenance manual DCF 280-
500.
4 Knock out the bolt with a sledge hammer.

5 Replace the bolt.

7 Load handling 1
7 Load handling
Table of Contents 7 Load handling

mm mm mm mm mm mm
7 Load handling................................................................................................. 3
7.1.1 Control lever .......................................................................................... 4
7.2 Lifting/lowering ........................................................................................... 8
7.2.2 Accumulator servo circuit ..................................................................... 15
7.2.3 Pressure reducer ................................................................................. 17
7.2.4 Servo filter ............................................................................................ 19
7.2.6 Control valve load handling ................................................................. 19
7.2.7 Lift cylinder ........................................................................................... 25
7.2.9 Mast ..................................................................................................... 25
7.2.10 Mast position sensor ............................................................................ 37
7.2.11 Lifting carriage ..................................................................................... 38
7.2.12 Pipes and hoses .................................................................................. 41
7.2.13 Load control valve ................................................................................ 42
7.4 Side shift ................................................................................................... 43
7.4.4 Servo filter ............................................................................................ 47
7.4.6 Side shift cylinder ................................................................................. 48
7.4.10 Fork mounting ...................................................................................... 49
7.4.12 Pipes and hoses .................................................................................. 49
7.5 Spreading ................................................................................................. 50
7.5.4 Servo filter ............................................................................................ 54
7.5.6 Side shift cylinder ................................................................................. 55
7.5.9 Pipes and hoses .................................................................................. 55
7.7 Tilt ............................................................................................................. 56
7.7.4 Servo filter ............................................................................................ 60
7.7.6 Load retention valve ............................................................................ 61
7.7.7 Tilt cylinder ........................................................................................... 62
7.7.9 Mast ..................................................................................................... 62
7.7.10 Pipes and hoses .................................................................................. 62

2 7 Load handling
7.9 Load carrier ............................................................................................... 63

7.9.1 Lift forks ................................................................................................ 63
7.9.2 Carpet boom ......................................................................................... 64
7.10 Other functions .......................................................................................... 65
7.10.5 Separate top lift attachment ................................................................. 65

7 Load handling – 7 Load handling 3
7 Load handling
mm mm mm mm mm mm
Position sensor, checking and

page
–
adjustment
2
3
1
1
2
1
4
007694
1. Alignment sensor .
2. Twistlocks sensor .
3. Spreading position sensor .
4. Position sensor, mast down .
5. Position sensor, lifting carriage up .

Check and adjust the position sensor as follows:
2 Check that the sensor in question is free of damage and dirt.
C-C
3 Check that the distance between the sensor and the indicator is
5±1 mm
5 ±1 mm.
4 Adjust if necessary.
009632
5±1 mm
Adjusting position sensor - indicator

4 7 Load handling – 7.1 Controls and instruments

7.1.1 Control lever
Control levers for hydraulic servo, description
page
–
a. Lift/lower.
LIFT - pull the lever backwards.
LOWER - push the lever forwards.
Lowering speed can only be varied by lever movement - en-
gine rpm has no effect.
b. Tilt.
REARWARD - pull the lever backwards.
FORWARD - move lever forward.
a b c d c. Side shift.
LEFT - move lever forward.
RIGHT - pull the lever backwards.
It is not possible to use side shift on the forks if fork spreading
is in its max or min position.
d. Fork spreading.
OUT - push the lever forwards.
IN - pull the lever backwards.
010688
Movement of the right fork. Side shift to desired position of left

fork and spread again.

7 Load handling – 7.1.1 Control lever 5
Control levers for electric servo, description

–
The load handling functions are controlled with fingertip-controlled lin-

ear levers.
The control levers are supplied voltage by and send a signal to the cab
a. Lift/lower (R8071).
LIFT - pull the lever backwards.
LOWER - push the lever forwards.
The lowering speed can only be varied through lever movement -
engine speed has no impact.
b. Tilt (R8072).
REARWARD - pull the lever backwards.
d/e FORWARD - pull the lever forwards.
c
b
a c. Side shift (R8073).
f LEFT - pull the lever forwards.
RIGHT - pull the lever backwards.
It is not possible to use side shift on the forks if fork spreading is
in its max or min position.
d. Fork spreading (R8074).
OUT - push the lever forwards.
IN - pull the lever backwards.
Movement of the right fork. Side shift to desired position of left fork
and spread again.
e. Rotation, attachment (R8074)

RIGHT side forward - push lever forwards.
LEFT side forward - pull lever backwards.
f. Emergency stop switch for servo circuits.
g
g. Opening locked twistlocks, attachment (S1002) .
Pull the switch sideways.
006182

6 7 Load handling – 7.1.1 Control lever
Control lever, description

–
The control lever (S815) is used to control the mast and attachment.
2 3
1 The lever sends voltage signals to the cab control unit (D790-1).
4 The control lever has four potentiometer-controlled functions and six
on/off functions.
5
Lifting/lowering
6
Lifting/lowering are controlled by moving the control lever forward
7 (lower - position 10) or rearward (lift - position 12).
8
Control system, group 8.4.8.1 ELSERV, menu 1.
12 9
Fork spreading
009711
When the top edge of the potentiometer (position 7) is pressed in, fork
11 10 spreading out is activated. When the bottom edge is pressed in, fork
1. Not used spreading in is activated.
2. Not used The signal can be checked from the diagnostic menu, see section 8
3. Side shift (S815-P3) Control system, group 8.4.9.1 ATTACH, menu 1.
4. Spread in (S815-T1.2)
Spreading (with separate top lift attachment)
5. Spread out (S815-T1.1)
6. Twistlock opening (S815-T2) at full contact
7. Fork spreading (S815-P4) When the switch is pressed at position 5, spreading in is activated.
When the switch is pressed at position 4, spreading out is activated.
7. Rotation (S815-P4)
8. Not used The signal can be checked from the diagnostic menu, see section 8
9. Tilt out Control system, group 8.4.9.3 ATTACH, menu 3.
10. Tilt in
11. Lower Side shift
12. Lift When the potentiometer (position 3) is pressed on the left side, side
shift left is activated. When the right side is pressed, side shift right is
activated.
Control system, group 8.4.9.1 ATTACH, menu 1.
Rotation
When the top edge of the potentiometer (position 7) is pressed in, ro-
tation clockwise is activated. When the bottom edge is pressed in, ro-
tation anticlockwise is activated.
Tilt
Tilt is controlled by moving the lever to the right (tilt out - position 10)
or the left (tilt in - position 12).

7 Load handling – 7.1.1 Control lever 7
Opening of twistlocks
When the switch (position 6) is activated, the twistlocks are opened if
the conditions for such are fulfilled.

8 7 Load handling – 7.2 Lifting/lowering
7.2 Lifting/lowering
Lifting/lowering, function description (hydraulic
page
–
servo)
8
7
3 C2
A 4
2 B2
T H
P
P2
P1 8
T A2 7
6
C1
EF
P
1 1 T
009692
1 The hydraulic oil pumps pump oil from See pressure plate on left Section 10 Common hydraulics, group
the hydraulic oil tank. frame beam. 10.4.3 Vane pump with fixed displacement
2 The pressure reducer reduces pressure P = 3.5 MPa Pressure reducer, description page 17
from the accumulators to servo pres-
sure.
3 The accumulator stores servo pressure. See pressure plate on left Accumulator servo circuit, description page
The non-return valve in the pressure re- frame beam. 15
ducer makes it possible to store the
pressure when the engine is shut off.
4 The servo filter cleans the oil upstream - Servo filter, description page 19
of the control levers.
5 The lifting/lowering control lever regu- - Section 9 Frame, body, cab and accesso-
lates servo pressure in proportion to le- ries, group 9.1 Controls and instruments
ver movement to the load handling
control valve.

7 Load handling – 7.2 Lifting/lowering 9

6 The servo pressure from the lifting/low- - Load handling control valve, description (hy-
ering control lever actuates the lifting/ draulic servo) page 20
lowering spool in the load handling con-
trol valve, which opens and regulates
pressure or releases pressure in propor-
tion to the servo pressure in the load
control valve.
7 The load control valve opens and directs - Load control valve, description page 42
pressure on to the lift cylinders.
8 The lift cylinders raise or lower the inner - Lift cylinder, description page 25
mast in relation to the outer mast. Lift masts, description page 25


Lifting/lowering, function description (electric

page
–
servo)

Emergency stop Disengaged Section 11 Common electrics , group 11.5.1.4 Emergency stop switch volt-
switch age
D5
5b
5a
6
D790-1
D797-1
7
D7
3 10
9
C2
8
2 A 4
T H
P
C
P2
P1
10
T 9
8
C1
EF
P
1 1 T
009679

1 The hydraulic oil pumps pump oil from the See pressure plate on left Section 10 Common hydraulics, group
hydraulic oil tank. frame beam. 10.4.3 Vane pump with fixed displace-
ment
from the hydraulic oil pump to servo pres-
sure.
3 The accumulator stores servo pressure. See pressure plate on left Accumulator servo circuit, description
The non-return valve in the pressure reduc- frame beam. page 15
er makes it possible to store the pressure
when the engine is shut off.


4 The servo filter cleans the oil upstream of - Servo filter, description page 19
the load handling control valve.
5a The lifting/lowering control lever (R8071) U = 0.5-4.5 V Section 9 Frame, body, cab and accesso-
sends the cab control unit (D790-1) a volt- Lower: U = <2.5 V ries, group 9.1 Controls and instruments
age signal proportional to lever movement. D5: Diagnostic menu, see section 8 Con-
Lift: U = >2.5 V
trol system, group 8.4.8.1 ELSERV, menu
0.5 V is the fastest lowering
1
speed and 4.5 V is the fastest
lift speed. Lower voltages
than 0.5 V and higher voltag-
es than 4.5 V are used to de-
tect malfunctions in cabling
and controls.
5b The control lever (S815-P1) sends the cab US815-P1 = 0.5-4.5 V Section 9 Frame, body, cab and accesso-
control unit (D790-1) a voltage signal pro- Lower: U ries, group 9.1 Controls and instruments
S815-P1 = <2.5 V
portional to lever movement. D5: Diagnostic menu, see section 8 Con-
Lift: US815-P1 = >2.5 V
trol system, group 8.4.8.1 ELSERV, menu
0.5 V is the fastest lowering 1
speed and 4.5 V is the fastest
lift speed. Lower voltages
than 0.5 V and higher voltag-
es than 4.5 V are used to de-
tect malfunctions in cabling
and controls.
6 The cab control unit (D790-1) transmits lift Checked by the control sys- Section 11 Common electrics, group
mass or lower mast on the CAN bus. tem; error shown with error 11.5.3.1 Cab control unit (D790-1)
code.
7 Lift or lower mast - Load handling control valve, description
The frame control unit (D797-1) sends cur- (electric servo) page 21
rent proportional to the lever movement to D5: Diagnostic menu, see section 8 Con-
the lift mast solenoid valve (Y6005) or the trol system, group 8.4.8.3 ELSERV, menu
lower mast solenoid valve (Y6004). 3 and 8.4.8.4 ELSERV, menu 4
8 The lift mast solenoid valve (Y6005) or low- - Load handling control valve, description
er mast solenoid valve (Y6004) guides ser- (electric servo) page 21
vo pressure in proportion to the control
current to the lift spool in the load handling
control valve, which opens and regulates
pressure or releases pressure in proportion
to the servo pressure in the load control
valve.
10 The lift cylinders raise or lower the inner - Lift cylinder, description page 25
mast in relation to the outer mast. Lift masts, description page 25


Lifting/lowering with freelift, function

page
–
description (electric servo)

Emergency stop Disengaged Section 11 Common electrics , group 11.5.1.4 Emergency stop switch volt-
switch age
D8
8b
8a
9
D790-1
D797-1 D797-2 D2
3,14 10
D14
17
6 16 D1
C2 12
D11 15 13
11 2
5 A 7
T H A2
P
C
P2
P1
17 1
T 16
11
15
C1 EF
P
4 4 T
009684

The mast down position sensor (B261) Mast down: U = 24 V Mast position sensor, description page 37
1
send the frame control unit (D797-1) a Mast up: U = 0 V D1: Diagnostic menu, see section 8 Control
voltage signal when the mast is down all system, group 8.4.11.4 FREELIFT, menu 1
the way.
The lifting carriage up position sensor Lifting carriage uplift max Mast position sensor, description page 37
2
(B260) sends the frame control unit with freelift cylinder: U = D2: Diagnostic menu, see section 8 Control
(D797-1) a voltage signal when the lifting 24 V system, group 8.4.11.4 FREELIFT, menu 1
carriage is in its top position.


3 The frame control unit (D797-1) transmits Checked by the control Section 11 Common electrics, group
mast position on the CAN bus. system; error shown with 11.5.3.2 Frame control unit (D797-1)
error code.
4 The hydraulic oil pumps pump oil from See pressure plate on left Section 10 Common hydraulics, group 10.4.3
the hydraulic oil tank. frame beam. Vane pump with fixed displacement
sure.
ducer makes it possible to store the pres-
sure when the engine is shut off.
7 The servo filter cleans the oil upstream of - Servo filter, description page 19
the load handling control valve.
8a The lifting/lowering control lever (R8071) U = 0.5-4.5 V Section 9 Frame, body, cab and accessories,
sends the cab control unit (D790-1) a Lower: U = <2.5 V group 9.1 Controls and instruments
voltage signal proportional to lever move- D8: Diagnostic menu, see section 8 Control
Lift: U = >2.5 V
ment. system, group 8.4.8.1 ELSERV, menu 1
0.5 V is the fastest lower-
ing speed and 4.5 V is the
fastest lift speed. Lower
voltages than 0.5 V and
higher voltages than 4.5 V
are used to detect mal-
functions in cabling and
controls.
8b The control lever (S815-P1) sends the US815-P1 = 0.5-4.5 V Section 9 Frame, body, cab and accessories,
cab control unit (D790-1) a voltage signal Lower: US815-P1 = <2.5 V group 9.1 Controls and instruments
proportional to lever movement. D8: Diagnostic menu, see section 8 Control
Lift: US815-P1 = >2.5 V
system, group 8.4.8.1 ELSERV, menu 1
0.5 V is the fastest lower-
ing speed and 4.5 V is the
fastest lift speed. Lower
voltages than 0.5 V and
higher voltages than 4.5 V
are used to detect mal-
functions in cabling and
controls.
9 Depending on mast position, the cab Checked by the control Section 11 Common electrics, group
control unit (D790-1) transmits lift car- system; error shown with 11.5.3.1 Cab control unit (D790-1)
riage, lift mast, lower carriage or lower error code.
mast on the CAN bus.


10 Lift or lower lifting carriage - Load handling control valve, description
The frame option control unit (D797-2) (electric servo) page 21
controls current proportional to lever D10: Diagnostic menu, see section 8 Control
movement to the solenoid valve for lift system, group 8.4.8.11 ELSERV, menu 11,
carriage (Y6005-2) or the solenoid valve 8.4.8.12 ELSERV, menu 12 and 8.4.11.4
for lower carriage (Y6004-2) on the load FREELIFT, menu 2
handling control valve.
11 The lift carriage solenoid valve (Y6005-2) - Load handling control valve, description
or lower carriage solenoid valve (Y6004- (electric servo) page 21
2) regulates servo pressure proportional
to the control current to the freelift spool
in the load handling control valve, which
opens and regulates pressure or releas-
es pressure in proportion to servo pres-
sure to the load control valve of the freelift
cylinder.
12 During lifting, the load control valve - Load control valve, description page 42
opens and leads pressure on to the freel-
ift cylinder with no limitation.
During lowering, the load control valve is
closed and limits the flow from the freelift
cylinder.
13 The freelift cylinder raises or lowers the - Lift cylinder, description page 25
lifting carriage in relation to the inner
mast.
14 Lift or lower mast - Load handling control valve, description
The frame control unit (D797-1) steers (electric servo) page 21
current proportional to lever movement to D14: Diagnostic menu, see section 8 Control
the solenoid valve for lift mast freelift system, group 8.4.8.11 ELSERV, menu 11
(Y6005-1) or the solenoid valve for lower and 8.4.8.12 ELSERV, menu 12
mast freelift (Y6004-1).
15 The lift mast freelift solenoid valve - Load handling control valve, description
(Y6005-1) or lower mast freelift solenoid (electric servo) page 21
valve (Y6004-1) regulates servo pres-
sure proportional to the control current to
the lift spool in the load handling control
valve, which opens and regulates pres-
sure or releases pressure in proportion to
servo pressure to the load control valve.
17 The lifting cylinders first raise the lifting - Lift cylinder, description page 25
carriage the last part to the top and then Lift masts, description page 25
the inner mast in relation to the outer
mast.


7 Load handling – 7.2.1 Hydraulic oil pump 15

page
–
See section 10 Common hydraulics, group 10.4.3 Vane pump with

fixed displacement.
7.2.2 Accumulator servo circuit

Accumulator servo circuit, description
page
–
The accumulator stores pressurised oil and ensures that there is servo
pressure for activating control valve functions. The accumulator is lo-
cated on the pressure reducer to the left on the frame near the gear-
box.
The accumulator is a diaphragm type and is divided into two spaces
by a diaphragm. One side of the diaphragm is pressurised with nitro-
gen gas. The other side is pressurised by hydraulic oil which compacts
the nitrogen gas.
Furthest up on the accumulator is a test outlet for checking gas pres-
sure and filling gas.
007695

16 7 Load handling – 7.2.2 Accumulator servo circuit
Accumulator servo circuit, replacement

page
–
NOTE
Safety.
3 Detach the accumulator from its mounting.
4 Replace the accumulator.
007696
6 Check the oil level and fill with hydraulic oil as necessary.

7 Load handling – 7.2.3 Pressure reducer 17
7.2.3 Pressure reducer

Pressure reducer, description
page
–
The pressure reducer reduces the pressure from the hydraulic oil
pump which supplies the servo circuit for control valve servo pressure.
The pressure reducer is located to the left on the frame near the gear-
box, mounted together with the servo pressure accumulator.
Servo pressure is stored in an accumulator for quicker start-up and for
3 emergency reduction of load. An integrated non-return valve prevents
1 pressure leakage from the accumulator when the machine is not in
use.
2
4
6 5
007697
1. Pressure reducer
2. Adjusting screw, servo pressure
3. Test outlet, servo pressure
4. Pressure feed from servo filter
5. Return to tank
6. Servo pressure to control valve

18 7 Load handling – 7.2.3 Pressure reducer
Pressure reducer, checking and adjusting servo

page
–
pressure
NOTE
Safety.
1 Operate and warm up the machine so that the hydraulic oil is at
operating temperature, at least 50 °C. As an alternative, operate
until the cooling fan is activated.
Safety.
4 Connect a pressure gauge (0–25 MPa) to the test outlet on the
pressure reducer.
007698
5 Start the engine and check the servo pressure. Compare with the
pressure plate.
M Pa Turn the steering wheel or activate a load handling function to ac-
tivate the hydraulic oil pumps. The servo pressure is higher than
the standby pressure of the hydraulic oil pumps.
6 If the pressure does not match the value specified on the pres-
MPa
sure plate, adjust the servo pressure adjusting screw until the
right pressure is obtained; see Pressure reducer, description
page 17. Slacken the lock nut and turn the adjusting screw.
MPa
MPa
NOTE
If the servo pressure is too high, a load handling function
MPa
must be activated so that servo pressure is used from the
MPa MPa MPa MPa accumulator for a reduction on the adjusting screw to be
007699
seen on the pressure gauge. Sometimes the engine has to

be shut off between the checks.
Clockwise: reduce pressure.
Counter-clockwise: increase pressure.
Safety.
measuring outlet.

7 Load handling – 7.2.4 Servo filter 19
7.2.4 Servo filter

Servo filter, description
page
–
The servo filter protects the control valve servo circuits from contami-
nants. The servo filter is located to the left on the frame near the gear-
box, between the pressure reducer and lift and tilt control valve.
The servo filter is a low-pressure filter with detachable filter insert. The
oil is cleaned when it passes through the filter insert’s filter material.
The filter insert is pressed against the upper section of the filter hous-
ing by a spring. Rubber gaskets seal between the insert and filter
housing. If the back pressure through the filter is too great the insert is
pressed down so that the oil passes by the insert. This occurs if the oil
is viscous (cold or incorrect viscosity) or if the filter insert is clogged.
007370
7.2.6 Control valve load handling

Load handling control valve, general
page
–
There are two types of load handling control valves - hydraulic servo
and electric servo.
The load handling control valve controls all load handling functions.
The control valve is located to the left on the frame near the gearbox.
The control valve is controlled hydraulically or with electric servo
valves.
The control valve has the following sections:
• Lift
• Freelift
• Tilt
• Side shift
• Spreading

20 7 Load handling – 7.2.6 Control valve load handling
Load handling control valve, description (hydraulic

page
–
servo)
3
2
1
10 5
11
6
7
8
9
12 10
11
007706
13
14
1. Servo pressure, spreading in 6. Pressure to lift cylinder 11. Pressure to side shift and spread-
2. Servo pressure, side shift left 7. Pressure from hydraulic oil pumps ing cylinder
3. Servo pressure, tilt out 8. Servo pressure, lower mast 12. Servo pressure, tilt in
4. Servo pressure, lift mast 9. Pressure to tilt cylinder 13. Servo pressure, side shift right
5. Return to tank (through filter) 10. Pressure to side shift and spreading 14. Servo pressure, spreading out
cylinder
For more information on load handling with the hydraulic servo, see
Lifting/lowering, function description (hydraulic servo) page 8, Side
shift, function description (hydraulic servo) page 43, Spreading, func-
tion description (hydraulic servo) page 50, Tilt, function description
(hydraulic servo) page 56 and Separate top lift attachment, description
page 65.
Actuation of the control valve is proportional to servo pressure. This
means that the magnitude and direction of the flow from the valve can
be controlled by adjusting the servo pressure to the control valve.
A low hydraulic pressure to servo pressure from the control levers ac-
tuates the spring-centred control spools in the control valve. The con-
trol spool for the function in question controls the main flow from the
hydraulic oil pumps to the hydraulic cylinders for that function. The
speed of the function is controlled by the flow, which is proportional to
the movement of the control lever.

7 Load handling – 7.2.6 Control valve load handling 21
Lift spool
If the lift control lever is activated when the mast is in the position for
lifting, the lift spool is pressurised and controls the direction and flow
of the oil from the hydraulic oil pumps to the lift cylinder.
Load handling control valve, description (electric

–
servo)
16
3 17
2 18
19
1
4 12
13
5
14
6
7 15
8
9
10
11
009674
1. Connection to spreading 9. Solenoid valve, tilt out (Y6010) 15. Solenoid valve, spreading out
2. Connection to side shift 10. Solenoid valve, side shift left (Y6018)
3. Connection to tilt cylinder (Y6020)

16. Solenoid valve, lift carriage
4. Return to tank (through filter) 11. Solenoid valve, spreading in (Y6005-2)
(Y6019)
5. Connection to freelift cylinder
12. Solenoid valve for lower mast 17. Solenoid valve, lower carriage
6. Connection to lift cylinder (Y6004-2)
7. Supply from hydraulic oil pumps (Y6004) or lower mast freelift
18. Auxiliary equipment
(Y6004-1)
8. Solenoid valve for lift mast (Y6005) 19. Auxiliary equipment
13. Solenoid valve, tilt in (Y6011)
or lift mast freelift (Y6005-1) 14. Solenoid valve, side shift right
(Y6021)

For more information on load handling with the electric servo, see Lift-
ing/lowering, function description (electric servo) page 10, Side shift,
function description (electric servo) page 45, Spreading, function de-
scription (electric servo) page 52, Tilt, function description (electric
servo) page 58 and Separate top lift attachment, description page 65.
The control valve is controlled proportionally by servo valves. This
means that the magnitude and direction of the flow from the valve can
be adjusted.
Electrically controlled pressure reducing valves (servo valves) convert
electrical current into a low hydraulic pressure that is proportional to
the current, known as the servo pressure. The servo pressure acts on
the spring-centred control spool in the control valve for the function in
question and thereby controls the main flow.
The speed of the function is controlled by the flow, which is proportion-
al to the movement of the control lever.
Lift spool
The lift spool controls direction and flow of oil to the lift cylinder.
Servo valve, lift mast

The servo valve for lifting is controlled electrically by the lift solenoid
valve (Y6005), which is activated by the frame control unit (D797-1).
The servo valve actuates the servo pressure to the lift spool. This pres-
sure is proportional to the control current to the solenoid valve.
Servo valve, lower mast

The servo valve for lowering is controlled electrically by the lower so-
lenoid valve (Y6004), which is activated by the frame control unit
(D797-1). The servo valve actuates the servo pressure to the lift spool.
This pressure is proportional to the control current to the solenoid
valve.
Freelift spool
The freelift spool controls direction and flow of oil to the freelift cylinder.
Servo valve, lift carriage

The lift carriage servo valve is controlled electrically by the lift carriage
solenoid valve (Y6022), which is activated by the frame option control
unit (D797-2). The servo valve directs servo pressure to the freelift
spool in proportion to the control current to the solenoid valve.

7 Load handling – 7.2.6 Control valve load handling 23
Servo valve, lower carriage

The lower carriage servo valve is controlled electrically by the lower
carriage solenoid valve (Y6023), which is activated by the frame op-
tion control unit (D797-2). The servo valve directs servo pressure to
the freelift spool in proportion to the control current to the solenoid
valve.
Hydraulic pressure for lift and tilt function, checking

page
–
and adjusting
NOTE
Safety.
1 Operate and warm up the machine so that the hydraulic oil reach-
es operating temperature, at least 50 °C.
tilt hydraulic pressure (position 1) or lift function (position 2) on
the control valve.
4 Start the engine.
5 Tilt or lift the mast to its end position while running the engine at
maximum rev.
2
010663
1. Measuring outlet, tilt function hydraulic pressure

2. Measuring outlet, lift function hydraulic pressure

6 Check that max. pressure matches hydraulic pressure for tilt or

lift on the pressure plate on the left frame beam.
7 Stop the engine
MPa
MPa
MPa
MPa
MPa MPa MPa MPa
007705
M Pa
8 If necessary, adjust the hydraulic pressure for the tilt (position 1)
or lift function (position 2) on the control valve.
Anticlockwise: reduce pressure.
Clockwise: increase pressure.
9 Repeat steps 5-9 until the hydraulic pressure matches the data
on the pressure plate.
measuring outlet.
010664
1 2
1. Adjusting hydraulic pressure of tilt function
2. Adjusting hydraulic pressure of lift function

7 Load handling – 7.2.7 Lift cylinder 25
7.2.7 Lift cylinder

Lift cylinder, description
page
–
The lift cylinders lift and lower the inner mast, which runs inside the
outer mast. The lower parts of the lift cylinders are fixed to the outer
mast, while their upper parts are fixed to the inner mast - one on the
right and one on the left of the mast.
The lift cylinders are equipped with end position damping. When the
cylinder approaches its bottom position, oil flow out from the cylinder
is limited. The oil is led out via a restrictor between the piston and the
cylinder bottom. To ensure that there is enough oil flow to lift the cylin-
der from its bottom position, the oil is led past the load control valve via
a non-return valve during lifting.
The lift cylinders are connected in parallel and fed from lift and tilt con-
trol valve, see Load handling control valve, general page 19.
007701

page
–
7.2.9 Mast
Mast, general
page
–
There are three different variants of mast available for the machine:
• Duplex standard
• Duplex freelift
• Triplex freelift
The Duplex alternatives have an outer and inner mast while Triplex
Freelift also has a centre mast.
Lift masts, description

page
–
The mast - whether Duplex or Triplex - is designed to provide a good

view. The number of welds has been minimised to ensure the highest
strength while keeping stress on mast components low.
The lower part of the mast is fixed to the frame by two shafts in two
double lugs on the front of the frame. The mast is also fixed to the
frame by two tilt cylinders.
The inner mast (inner and centre on Triplex) is moved laterally via sup-
port rollers in the outer end of the outer mast and the lower end of the
inner mast.

26 7 Load handling – 7.2.9 Mast
Duplex standard
The lower parts of the lift cylinders are fixed to the outer mast, while
6
their upper sections are fixed to the inner mast. When oil is forced into
5
the lift cylinders, the piston rods in the cylinders are forced out and the
inner mast is lifted. The chain which is fixed to the carriage (and the
outer mast), runs over sprockets at the top of the inner mast. This also
lifts the carriage at the same time as the inner mast.
4
7
Hydraulic hoses and cables run along the left side to power the func-
tions of any external attachment.
8
The lift cylinders for the mast have end position damping; see Lift cyl-
3 inder, description page 25.
9
2
4
1 10
009710
Duplex standard mast

1. Attachment to frame 2. Load control valves
3. Connection, lift cylin- 4. Inner mast
ders
5. Lifting eyes 6. Sprocket
7. Lift cylinder 8. Lifting chain
9. Chain tensioner 10. Outer mast

7 Load handling – 7.2.9 Mast 27
Duplex freelift
5
The mast consists of an outer mast and an inner mast, made from high
strength steel, with a minimum number of welds for highest strength.
4 The inner mast runs inside the outer mast, and is lifted and lowered by
6 the lift cylinders. Mast wheels and support rollers between the inner
and outer masts guide the inner mast in the outer mast and reduce fric-
7 tion between the two parts of the mast.
3
The freelift spool in the load handling control valve direct pressure to
the freelift cylinder. Oil is pressed into the freelift cylinders. The piston
rod end of the freelift cylinders houses a sprocket over which the chain
2 8
runs. The chain is attached to the carriage (and in the inner mast),
which means that the carriage is lifted when the piston rods of the
9
freelift cylinders are pressed out.
10 When the freelift cylinders reach their end position, the carriage up po-
1 sition sensor (B260) sends a signal to the control system and pressure
009704
11 to the freelift cylinder is cut off. The lift spool in the load handling con-
trol valve instead direct pressure to the lift cylinder, oil is pressed into
Duplex freelift mast the lift cylinders and their piston rods lift the inner mast.
1. Chain tensioner 2. Lifting chain Hydraulic hoses and cables run along the left side to power the func-
3. Freelift cylinder 4. Hoses tions of any external attachment.
5. Lift cylinders 6. Lifting eyes
7. Hydraulic connec- 8. Load control valves The lift cylinders for the Duplex freelift mast have end position damp-
tion ing; see Lift cylinder, description page 25.
9. Inner mast 10. Outer mast
11. Attachment to
frame

Triplex freelift
9
8
10 The mast consists of an outer mast, a centre mast and an inner mast
- all made of high-strength steel and having a minimal number of welds
7
to generate the highest strength. The inner mast runs inside the centre
mast, which in turn runs inside the outer mast. The masts are raised
and lowered by the lift cylinders. Mast wheels and support rollers are
6 found between the masts, holding them together and reduce friction
between mast components.
5 The freelift spool in the load handling control valve direct pressure to
11
the freelift cylinder. Oil is pressed into the freelift cylinders. The piston
4
12 rod end of the freelift cylinders houses a sprocket over which the chain
3 runs. The chain is attached to the carriage (and in the inner mast),
7 which means that the carriage is lifted when the piston rods of the
2
5 freelift cylinders are pressed out.
When the freelift cylinders reach their end position, the carriage up po-
13
009699
sition sensor (B260) sends a signal to the control system and pressure
1 to the freelift cylinder is cut off. The lift spool in the load handling con-
Triplex mast trol valve instead direct pressure to the lift cylinder, oil is pressed into
1. Attachment to 2. Centre mast the lift cylinders and their piston rods lift the inner mast.
frame The chain attached to the inner mast and outer mast runs over sprock-
3. Inner mast 4. Lift cylinders ets at the top of the centre mast, which means that the inner mast is
5. Load control valve 6. Freelift cylinders
raised at the same time as the centre mast.
7. Chain tensioner 8. Hoses
9. Sprocket, freelift 10. Sprocket Hydraulic hoses and cables run along the left side to power the func-
11. Lifting chain 12. Hydraulic connection tions of any external attachment.
13. Outer mast The lift cylinders for the Triplex freelift mast have end position damp-
ing; see Lift cylinder, description page 25.
Mast, removing
page
–
NOTE
Safety.
1 Remove the lifting carriage; see Lifting carriage, removing page
38.

2 Connect lifting equipment to the the mast’s lifting eyes in a secure

manner so the mast does not tip when lifted.
3 Start the engine and tilt the mast forwards as far as possible.
4 Stop the engine
5 Turn the start key to position I and activate the hydraulic functions
to depressurise the hydraulic system.
er.
007786
7 Position a receptacle under the hydraulic connections of the mast

to catch oil spill.
8 Mark up and detach the electrical connections from the mast.
NOTE
007717

9 Position a receptacle under the hydraulic connections of the

2 breast to catch oil spill.
10 Mark and detach the mast’s hydraulic connections on the breast.
1 Let the oil run out.
NOTE
007716
1. Connections for fork spreading

2. Connections for side shift
11 Undo the electrical connectors for the mast.
Undo the connectors and protect the terminals by greasing them
with contact grease. Then loosely insert the connectors.
12 Fasten one of the tilt cylinders in the lifting equipment (overhead

crane).

13 Release the tilt cylinder from the mast.

Remove the cylinder shaft. If necessary, use the threaded hole
and a puller to press the shaft out.
Start the engine and retract the cylinder so that it comes loose
from the mounting in the mast. Switch off the engine.
Save the spacers circlips. Refit the shaft in the tilt cylinder.
Lower the cylinder onto a block of wood. Then slacken and re-
move the lifting equipment (overhead crane).
Repeat the procedure for the other cylinder.
14 Tension the lifting equipment. Do not lift the mast.
15 Release the mast from the chassis.
WARNING
The mast can swing out when it is released from the
machine.
This can cause personal injury!
Stand in the mast as depicted.
16 Undo the circlips and remove the shafts which fix the mast to the
frame.

17 Lift the mast away and lay it on the ground.

18 Undo the lifting equipment (travelling crane).
Mast, installing
page
–
NOTE
Safety.
CAUTION
Overfilling of oil.
Leakage and environmental damage.
Check the hydraulic oil level with all hydraulic cylin-

ders fully retracted.
1 Stop the engine

er.
3 Connect the lifting equipment to the mast in a secure manner so
that the mast does not tip when lifted. Lift the mast from the
ground.
4 Before reinstalling the mast, the shafts and bearing surfaces
must be checked for deep grooves/scratches. Fibres must not
extend over the bearing surface. Replace any shaft, bearing or
seal that shows signs of damage.
007791

5 Suspend the mast vertically and lift the mast into place. It is im-
portant that the lifting equipment is connected to the mast’s lifting
eyes in a secure manner.
NOTE
The mast is attached to the machine’s frame with strong shafts
which run in maintenance-free bearings.
It is most important that bearing surfaces are absolutely clean
when the mast is installed.
The shafts and bearings mentioned above must NEVER be lu-
bricated with oil or grease.
007786
6 Align the mast and position the shafts in each mast mounting.
Then secure the shafts and fit the circlips.
7 Use suitable lifting equipment (overhead crane) and lower a tilt

cylinder to the mounting in the mast.
8 Start the engine and activate the tilt function. Extend the tilt cylin-
der’s piston rod until it fits against the mounting in the mast.
9 Stop the engine

10 Connect the tilt cylinder to the mast, align the tilt cylinder and fit
the spacers. Fit the circlips.
11 Repeat points 7-10 for the other tilt cylinder.
12 Remove the lifting equipment from the mast.
13 Grease the connectors with contact grease and join them up.
14 Remove the plugs and attach the mast’s hydraulic hoses.

2
1
007716
1. Connections for fork spreading

2. Connections for side shift

15 Remove the plugs and connect the hydraulic hoses to the lift cyl-
inders.
16 Turn on the power supply and start the engine.
17 Check the hydraulic connections for leaks.
18 Check the mast functions.
19 Install the lifting carriage; see Lifting carriage, installing page 40.
007717

Support roller, checking, adjusting and, if necessary,

page
–
replacement
NOTE
Safety.
1 Remove the mast, see Mast, removing page 28.
2 Divide the inner and outer mast.
3 Check the distance between the mast members with an inside
calliper in the centre of the member. Move the inside calliper
along the width of the members to register the shortest distance.
007787
4 Use a Vernier calliper to measure the inside calliper and note the
value.
Vernier calliper with measurement length 1500 mm

and inside callipers.
5 Measure the distance between the highest points of the support
rollers with a Vernier calliper. Compare this with the previously
noted dimension.
The distance between the support rollers should be 2-3 mm
greater than the distance between mast members, as measured
with the Vernier and inside callipers. Adjust the distance with 1
mm shims as necessary.

7 Load handling – 7.2.10 Mast position sensor 37
6 Undo the four screws securing the support rollers (use Loctite
when refitting the screws). Clean the support roller contact sur-
face to the mat. Fit 1 mm shims in pairs between the mast mem-
ber and support roller.
NOTE
Distribute the shims so that they are not all on the same side
of the inner mast (or carriage when adjusting its support roll-
ers).
7 Screw the support roller down and check the dimension with a
Vernier calliper. Lock the screws with Loctite.
NOTE
Replace support rollers as necessary.
8 Slide the inner and outer mast together.
9 Repeat steps 3-7 to check and adjust the carriage’s support roll-
ers.
005247
a. Measure the inner dimension in the inner mast.

b. Measure the distance across the support rollers on the car-
riage.
7.2.10 Mast position sensor

Mast position sensor, description
page
–
The machine has two position sensors on the mast for switching be-
tween freelift and standard lift
Mast position is used to determine if the lift or freelift section of the load
handling control valve is to regulate when the lifting/lowering control
lever is activated.
The mast down position sensor (B261) is located on the rear of the
outer mast on the left side and indicates toward the inner mast. The
position sensor detects when the mast is in its bottom position.
The carriage up position sensor (B260) is located on the left carriage
plate in the lifting carriage. It detects when the lifting carriage reaches
the top of the inner mast. Freelift lifts the carriage in two stages - first
with the freelift cylinder and then with the lift cylinders. The carriage up
position sensor (B260) detects when the freelift cylinder has reached
its top position.
The position sensor (B260) transmits signals to the KDU frame control
unit (D797-1) on machines with hydraulic servo and to the KDU frame
option control unit (D797-2) on machines with electric servo. The po-
sition sensor (B261) sends a signal to the KDU frame option control
unit (D797-2). The signal can be checked with the diagnostic menu;
see section 8 Control system, group 8.4.11.4 HYD, menu 1.

38 7 Load handling – 7.2.11 Lifting carriage
7.2.11 Lifting carriage

Lifting carriage, description
page
–
The lifting carriage houses the fork mountings and lift forks. It runs
1 2 3 4 5
along the inner mast with support rollers and mast wheels mounted on
bearings. During lifting, oil is forced into the lift cylinders, the piston
rods in the cylinders are forced out and the inner mast is lifted. The
chain which is fixed to the carriage (and the outer mast), runs over
sprockets at the top of the inner mast. This also lifts the carriage at the
same time as the inner mast.
During freelift, the freelift cylinder raises the lifting carriage in re-
6 lation to the mast.
2 1
See also Fork mounting, description page 49, Side shift and spreading
7
3 cylinders, description page 48 and Lift forks, description (standard
4 forks) page 63.
5
2
002789
1. Fork mounting
2. Support rollers
3. Side shift and spreading cylinders
4. Lifting carriage
5. Lift fork
6. Fork rollers
7. Mast wheel
Lifting carriage, removing

page
–
NOTE
Safety.
1 Start the machine and set the mast vertical. Lower the mast.
NOTE
The lifting carriage must be placed on a flat surface and se-
cured. It could otherwise tip over when the machine is re-
versed away.
3 Remove the lift forks.
5 Position a receptacle under the hose connections of the mast to
catch spill oil.
007719

7 Load handling – 7.2.11 Lifting carriage 39
6 Mark up and detach the hydraulic hoses from the lifting carriage.
NOTE
007718 7 Lift the carriage slightly with the lifting equipment to relieve the
load on the lifting chains.
Slacken the lower nuts and release the chain tensioners from the
lifting carriage.
8 Fasten weights in or secure the chains with rope to prevent them
from travelling across the sprocket when the mast is raised.
007720
9 Start the machine and raise the mast. Lift and lower the lifting car-
riage with lifting equipment as necessary so that the carriage is
free from the mast. Back away from the mast or move the lifting
carriage.
WARNING
The lifting carriage can swing out when it is released
from the mast. Make sure it is secured with lifting
equipment.
007722

40 7 Load handling – 7.2.11 Lifting carriage
Lifting carriage, installing

page
–
NOTE
Safety.
1 Start the machine and set the mast vertical.
2 Raise the mast so high that there is room for the lifting carriage.
3 Connect lifting equipment to the lifting carriage in a secure man-
ner and run the machine toward or position the lifting carriage in
the mast with lifting equipment.
4 Lower the mast.
007723
5 Fasten the lifting chain tensioners in the lifting carriage.

007720

7 Load handling – 7.2.12 Pipes and hoses 41
6 Tension the chains with the chain tensioners. Check that the
chains are tensioned equally.
7 Measure the ground clearance of the lifting carriage. The dis-
tance must be equal on the right and left sides, with a tolerance
of ±5 mm. Adjust further with the chain tensioner if necessary.
007724
8 Connect the hydraulic hoses to the lifting carriage in accordance

with the marking.
NOTE
9 Undo the lifting equipment (travelling crane).
10 Turn on the power supply and start the engine.
11 Activate the load handing functions. Check the hydraulic connec-
tions for leaks.
12 Check the oil level in the hydraulic oil tank when all cylinders are
007718
fully retracted. Top up as necessary.

page
–

42 7 Load handling – 7.2.13 Load control valve
7.2.13 Load control valve

Load control valve, description
page
–
The load control valves of the lift cylinders are located in the piston-
side connection while the load control valves of the freelift cylinders
1 are located in the rod-side connection.
The valve contains a spring-loaded guide piston and a movable throt-
tle plate that work together to give a constant through-flow, regardless
of size of the load. The maximum lowering speed is constant and can-
not be adjusted regardless of the weight of the load.
For lifting, the throttle plate and the guide piston are in the through-flow
2 position, allowing the unobstructed passage of the oil. For lowering,
the throttle plate assumes a throttle position. The internal pressure
drop in the valve and the pre-load force of the guide piston’s spring
counteract each other, balancing the position of the guide piston, with
a corresponding size of restriction gap. Big load - small gap, small load
- big gap.
000632
1. Lift cylinder
2. Load control valve

7 Load handling – 7.4 Side shift 43
7.4 Side shift

Side shift, function description (hydraulic servo)
page
–
3 C2
A 4
2 A1 A1
7
T H
P
P2
P1
T B1 B1
6 7
C1
EF
P
1 1 T
009693
1 The hydraulic oil pumps pump oil from See pressure plate on Section 10 Common hydraulics , group 10.4.3
the hydraulic oil tank. left frame beam. Vane pump with fixed displacement
from the hydraulic oil pump to servo
pressure.
3 The accumulator stores servo pressure. See pressure plate on Accumulator servo circuit, description page
The non-return valve in the pressure re- left frame beam. 15
5 The side shift control lever directs servo - Section 9 Frame, body, cab and accessories,
pressure in proportion to lever move- group 9.1 Controls and instruments
ment to load handling control valve.

44 7 Load handling – 7.4 Side shift

6 The servo pressure from the side shift - Load handling control valve, description (hy-
control lever actuates the side shift draulic servo) page 47
spool in the load handling control valve,
which changes position and pressurises
the side shift and spreading cylinders.
7 The side shift and spreading cylinders - Lifting carriage, description page 38
slide the fork mounting laterally in the Fork mounting, description page 49
lifting carriage.
Side shift and spreading cylinders, descrip-
tion page 48


7 Load handling – 7.4 Side shift 45
Side shift, function description (electric servo)

page
–

Emergency stop Disengaged Section 11 Common electrics, group 11.5.1.4 Emergency stop switch volt-
switch age
D5
5b
5a
6
D790-1
D797-2
D7 7
3 C2
8
A 4
2 A1 A1
9
T H
P C
P2
P1
T B1 B1
9
8
C1 EF
P
T
1 1
009680
pressure.
of the load handling control valve.

46 7 Load handling – 7.4 Side shift

5a The side shift control lever (R8073) U = 0.5-4.5 V Section 9 Frame, body, cab and accesso-
sends the cab control unit (D790-1) a Left: U = <2.5 V ries, group 9.1 Controls and instruments
voltage signal proportional to lever D5: Diagnostic menu, see section 8 Control
Right: U >2.5 V
movement. system, group 8.4.8.1 ELSERV, menu 1
0.5 V is the highest speed
for side shift left and 4.5 V
is the highest speed for
side shift right. Voltage
lower than 0.5 V and
higher than 4.5 V is used
to detect defects in cable
harnesses and controls.
5b The control lever (S815-P3) sends the US815-P3 = 0.5-4.5 V Section 9 Frame, body, cab and accesso-
cab control unit (D790-1) a voltage sig- Right: US815-P3 = <2.5 V ries, group 9.1 Controls and instruments
nal proportional to lever movement. D5: Diagnostic menu, see section 8 Control
Left: US815-P3 = >2.5 V
for side shift right and 4.5
V is the highest speed for
side shift left. Voltage
lower than 0.5 V and
higher than 4.5 V is used
to detect defects in cable
harnesses and controls.
6 The cab control unit (D790-1) transmits Checked by the control Section 11 Common electrics, group
side shift left or side shift right on the system; error shown with 11.5.3.1 Cab control unit (D790-1)
CAN bus. error code.
7 The frame option control unit (D797-2) U = 24 V Section 11 Common electrics, group
activates the solenoid valve for side 11.5.3.3 Cab control unit (D797-2)
shift left (Y6020) or the solenoid valve D7: Diagnostic menu, see section 8 Control
for side shift right (Y6021). system, group 8.4.8.7 ELSERV, menu 7 and
8.4.8.8 ELSERV, menu 8
8 The solenoid valve for side shift left - Load handling control valve, description
(Y6020) or the solenoid valve for side (electric servo) page 47
shift right (Y6021) directs servo pres-
sure to the side shift spool in the load
handling control valve, which changes
position and directs pressure to the side
shift and spreading cylinders.
9 The side shift and spreading cylinders - Lifting carriage, description page 38
slide the fork mountings laterally on the Fork mounting, description page 49
lifting carriage.
tion page 48


7 Load handling – 7.4.1 Hydraulic oil pump 47

page
–

fixed displacement.

page
–
See Accumulator servo circuit, description page 15.

page
–
Se Pressure reducer, description page 17
7.4.4 Servo filter

page
–
See Servo filter, description page 19

page
–
servo)
Side shift is controlled by a separate section of the load handling con-
trol valve.
For general information on the control valve, see Load handling con-
trol valve, description (hydraulic servo) page 20.
For more information on side shift, see Side shift, function description
(hydraulic servo) page 43.
Side shift spool

When the side shift control lever is activated, the side shift spool is
pressurised and controls the direction and flow of oil from the hydraulic
oil pumps to the spreading cylinders. See Side shift and spreading cyl-
inders, description page 48.

page
–
servo)
The load handling control valve controls all load handling functions.
See also Load handling control valve, description (electric servo) page
21.
For more information on side shift, see Side shift, function description
(electric servo) page 45.
Side shift spool

The side shift spool controls the direction and flow of oil to the side shift
cylinders.

48 7 Load handling – 7.4.6 Side shift cylinder
Servo valve, side shift left

On machines with electric servo, the servo valve for side shift left is
controlled electrically by the solenoid valve for side shift left (Y6020),
which is activated by the frame option control unit (D797-2). The servo
valve directs the servo pressure to the side shift spool at a rate propor-
tional to the control current to the solenoid valve.
Servo valve, side shift right

On machines with electric servo, the servo valve for side shift right is
controlled electrically by the solenoid valve for side shift right (Y6021)
which is activated by the frame option control unit (D797-2). The servo
valve directs the servo pressure to the side shift spool at a rate propor-
tional to the control current to the solenoid valve.
7.4.6 Side shift cylinder

Side shift and spreading cylinders, description
page
–
The side shift and spreading cylinders are located between the lifting
1 2 3 4 5
carriage and the fork mountings. The cylinders slide the fork mount-
ings laterally on the lifting carriage during spreading and side shift. The
side shift and spreading cylinders are connected to both the spreading
and side shift sections of the load handling control valve.
During spreading, the upper cylinder is pressurised and moves the
right fork mounting. The left fork mounting is stationary.
During side shift, the piston side of one cylinder (the upper for side shift
6 right and the lower for side shift left) is pressurised. When the hydraulic
2 1 cylinder is extended, oil is pressed from the piston side to the rod side
7 of the other cylinder, compressing it. This causes the two forks to
3 move an equal distance laterally.
4
5
2
002789
1. Fork mounting
2. Support rollers
4. Lifting carriage
5. Lift fork
6. Fork rollers
7. Mast wheel

7 Load handling – 7.4.10 Fork mounting 49

page
–
7.4.10 Fork mounting

Fork mounting, description
page
–
The fork mounting is the movable part of the lifting carriage that holds
1 2 3 4 5
the lift forks. Each fork mounting can move laterally. The top edge of
each mounting is suspended with four fork rollers mounted on bear-
ings. At the bottom, it rests on the lifting carriage on two support roll-
ers. Fork rollers and support rollers reduce friction and wear during
side shift and spreading.
Each fork (pin type) is attached to the fork mounting with a shaft.
The shaft can angle the fork upward to prevent damage if the mast is
6 tilted too far forward.
2 1
Located between the fork mountings and lifting carriage are the side
7
3 shift and spreading cylinders. The cylinders move the fork mounting
4 laterally during spreading and/or side shift.
5
See also Lifting carriage, description page 49, Side shift and spread-
2 ing cylinders, description page 48 and Lift forks, description (standard
002789
forks) page 63.

1. Fork mounting
2. Support rollers
4. Lifting carriage
5. Lift fork
6. Fork rollers
7. Mast wheel

page
–
See Lifting carriage, description page 38.

page
–

50 7 Load handling – 7.5 Spreading
7.5 Spreading
Spreading, function description (hydraulic
page
–
servo)
3 C2
A 4
2 A1 A1
7
T H
P C
P2
P1
T B1 B1
6 7
C1
EF
P
T
1 1
009694
pressure.
5 The spreading control lever directs ser- - Section 9 Frame, body, cab and accesso-
vo pressure in proportion to lever move- ries, group 9.1 Controls and instruments
ment to the load handling control valve.

7 Load handling – 7.5 Spreading 51

6 The servo pressure from the spreading - Load handling control valve, description (hy-
control lever actuates the spreading draulic servo) page 54
the upper side shift and spreading cylin-
der.
7 The upper side shift and spreading cyl- - Lifting carriage, description page 38
inder moves the right fork mounting lat- Fork mounting, description page 49
erally.
tion page 55


52 7 Load handling – 7.5 Spreading
Spreading, function description (electric servo)

page
–

switch age
5b D5
5a
6
D790-1
D797-2
D7 7
3 C2
8
A 4
2 A1 A1
9
T H
P C
P2
P1
T B1 B1
9
8
C1
EF
P
T
1 1
009681

1 The hydraulic oil pumps pump oil from See pressure plate on Section 10 Common hydraulics , group 10.4.3
the hydraulic oil tank. left frame beam. Vane pump with fixed displacement
pressure.
3 The accumulator stores servo pressure. See pressure plate on Accumulator servo circuit, description page
The non-return valve in the pressure re- left frame beam. 15

7 Load handling – 7.5 Spreading 53

5a The spreading control lever (R8074) U = 0.5-4.5 V Section 9 Frame, body, cab and accessories ,
sends the cab control unit (D790-1) a Out: U = <2.5 V group 9.1 Controls and instruments
voltage signal proportional to lever D5: Diagnostic menu, see section 8 Control
In: U = >2.5 V
movement. system, group 8.4.8.1 ELSERV, menu 2
0.5 V is the highest
speed for spreading out
and 4.5 V is the highest
speed for spreading in.
Voltage lower than 0.5
V and higher than 4.5 V
is used to detect de-
fects in cable harness-
es and controls.
cab control unit (D790-1) a voltage sig- Out: US815-P4 = <2.5 V group 9.1 Controls and instruments.
In: US815-P4 = >2.5 V
0.5 V is the highest
speed for spreading out
and 4.5 V is the highest
speed for spreading in.
Voltage lower than 0.5
V and higher than 4.5 V
is used to detect de-
fects in cable harness-
es and controls.
6 The cab control unit (D790-1) transmits Checked by control Section 11 Common electrics, group 11.5.3.1
spreading in or spreading out on the system, error shown Cab control unit (D790-1)
CAN bus. with error code.
7 The frame option control unit (D797-2) U = 24 V Section 11 Common electrics, group 11.5.3.3
activates the spreading in solenoid Cab control unit (D797-2)
valve (Y6019) or the spreading out sole- D7: Diagnostic menu, see section 8 Control
noid valve (Y6018). system, group 8.4.8.9 ELSERV, menu 9 and
8 The spreading in solenoid valve (Y6019) - Load handling control valve, description (elec-
or spreading out solenoid valve (Y6018) tric servo) page 55
directs servo pressure to the spreading
the piston side of the side shift and
spreading cylinder.
9 The upper side shift and spreading cyl- - Fork mounting, description page 49
inder moves the right fork mounting lat- Side shift and spreading cylinders, description
erally. page 55


54 7 Load handling – 7.5.1 Hydraulic oil pump

page
–

fixed displacement.

page
–

page
–
Se Pressure reducer, description page 17
7.5.4 Servo filter

page
–
See Servo filter, description page 19

page
–
servo)
Spreading is controlled by a separate section of the load handling con-
trol valve.
For more information on spreading, see Spreading, function descrip-
tion (hydraulic servo) page 50.
Spreader spool
When the spreading control lever is activated, the spreading spool is
pressurised. The spool controls the direction and oil flow from the hy-
draulic oil pump to the spreading cylinders. See Side shift and spread-
ing cylinders, description page 55.

7 Load handling – 7.5.6 Side shift cylinder 55

page
–
servo)
Spreading is controlled by a separate section of the load handling con-

trol valve.
trol valve, description (electric servo) page 21.
tion (electric servo) page 52.
Servo valve, spreading out

The spreading out servo valve is controlled electrically by the spread-
ing out solenoid valve (Y6018), which is activated by the frame option
control unit (D797-2). The servo valve directs servo pressure to the
spreading spool in proportion to the control current to the solenoid
valve.
Servo valve, spreading in

The spreading in servo valve is controlled electrically by the spreading
in solenoid valve (Y6019), which is activated by the frame option con-
trol unit (D797-2). The servo valve directs servo pressure to the
spreading spool in proportion to the control current to the solenoid
valve.
7.5.6 Side shift cylinder

Side shift and spreading cylinders, description
page
–
See Side shift and spreading cylinders, description page 48

page
–

page
–
See Lifting carriage, description page 38.

page
–

56 7 Load handling – 7.7 Tilt
7.7 Tilt
Tilt, function description (hydraulic servo)
page
–
3 C2
A 4 8
2 7
T H A1
P
P2
P1 8
T B1 7
6
C1
EF
P
T
1 1
009695
pressure.
5 The tilt control lever directs servo pres- - Section 9 Frame, body, cab and accesso-
sure to the load handling control valve in ries, group 9.1 Controls and instruments
proportion to lever movement.

7 Load handling – 7.7 Tilt 57

6 The servo pressure from the tilt control - Load handling control valve, description (hy-
lever acts on the tilt slide in the load han- draulic servo) page 60
dling control valve, which changes posi-
tion and pressurises the tilt cylinders.
7 The load retention valve opens and di- - Load retention valve, description page 61
rects the pressure on to the tilt cylinders.
8 The tilt cylinders angle the mast in rela- - Lift masts, description page 25
tion to the frame. Tilt cylinder, description page 62


58 7 Load handling – 7.7 Tilt
Tilt, function description (electric servo)

page
–

switch age
D5
5b
5a
6
D790-1
D797-1
D7 7
3 C2
8
A 4 10
2 9
T H A1
P C
P2
P1 10
T B1 9
8
C1
EF
P
1 1 T
009682

2 The pressure reducer reduces pres- P = 3.5 MPa Pressure reducer, description page 17
sure from the hydraulic oil pump to ser-
vo pressure.
3 The accumulator stores servo pres- See pressure plate on left Accumulator servo circuit, description page
sure. The non-return valve in the pres- frame beam. 15
sure reducer makes it possible to store
the pressure when the engine is shut
off.

7 Load handling – 7.7 Tilt 59

5a The tilt control lever (R8072) sends the U = 0.5-4.5 V Section 9 Frame, body, cab and accessories,
cab control unit (D790-1) a voltage sig- Out: U = <2.5 V group 9.1 Controls and instruments
In: U = >2.5 V
for tilt out and 4.5 V is the
highest speed for tilt in.
Voltage lower than 0.5 V
and voltage higher than
4.5 V is used to detect de-
fects in cables and con-
trols.
cab control unit (D790-1) a voltage sig- In: US815-P2 = >2.5 V group 9.1 Controls and instruments
Out: US815-P2 = >2.5 V
for tilt in and 4.5 V is the
highest speed for tilt out.
Voltage lower than 0.5 V
and voltage higher than
4.5 V is used to detect de-
fects in cables and con-
trols.
6 The cab control unit (D790-1) transmits Checked by control sys- Section 11 Common electrics, group
tilt in or tilt out on the CAN bus. tem, error shown with er- 11.5.3.1 Cab control unit (D790-1)
ror code.
7 The frame control unit (D797-1) acti- U = 24 V Section 11 Common electrics, group
vates the tilt in solenoid valve (Y6011) 11.5.3.3 Cab control unit (D790-2)
or the tilt out solenoid valve (Y6010). D7: Diagnostic menu, see section 8 Control
system, group 8.4.8.5 ELSERV, menu 5 and
8 The tilt in solenoid valve (Y6011) or the - Load handling control valve, description
tilt out solenoid valve (Y6010) directs (electric servo) page 60
servo pressure to the tilt spool in the
load handling control valve, which
changes position and pressurises the
tilt cylinders.
9 The load retention valve opens and di- - Load retention valve, description page 61
rects the pressure on to the tilt cylin-
ders.
10 The tilt cylinders angle the mast in rela- - Lift masts, description page 25
tion to the frame. Tilt cylinder, description page 62


60 7 Load handling – 7.7.1 Hydraulic oil pump

page
–

fixed displacement.

page
–

page
–
See Pressure reducer, description page 17.
7.7.4 Servo filter

page
–
See Servo filter, description page 19.

page
–
servo)
Tilting is controlled by a separate section of the load handling control
valve.
For more information about tilting, see Tilt, function description (hy-
draulic servo) page 56.
Tilt spool
When the tilt control lever is activated, pressure is fed to the tilt spool,
which controls the direction and flow of oil from the hydraulic oil pumps
to the tilt cylinders.

page
–
servo)
Tilt is controlled by a separate section of the load handling control

valve. See also Load handling control valve, description (electric ser-
vo) page 21.
For more information about tilting, see Tilt, function description (elec-
tric servo) page 58.
Tilt spool
When the servo valves are activated, pressure is fed to the tilt spool,
which controls the direction and flow of oil from the hydraulic oil pumps
to the tilt cylinders.

7 Load handling – 7.7.6 Load retention valve 61
Servo valve, tilt out

On machines with electric servo, the servo valve for tilt out is controlled
electrically by the tilt out solenoid valve (Y6010), which is activated by
the frame control unit (D797-1). The servo valve actuates the servo
pressure to the tilt spool. This pressure is proportional to the control
current to the solenoid valve.
Servo valve, tilt in

On machines with electric servo, the servo valve for tilt in is controlled
electrically by the tilt in solenoid valve (Y6011), which is activated by
the frame control unit (D797-1). The servo valve actuates the servo
pressure to the tilt spool. This pressure is proportional to the control
current to the solenoid valve.
7.7.6 Load retention valve

Load retention valve, description
page
–
The load retention valves are mounted on the tilt cylinders, by the hy-
draulic connection to the rod side. The load retention valve prevents
the tilt cylinders from moving faster than the pressure applied from the
load handling control valve. This prevents unwanted tilting forwards,
which can occur if there is a heavy load or high lift height. The load re-
tention valve also makes the tilting movement more controlled.
2
005236
1. Tilt cylinder
2. Load retention valve

62 7 Load handling – 7.7.7 Tilt cylinder
7.7.7 Tilt cylinder

Tilt cylinder, description
page
–
The tilt cylinders sit between the mast and the frame and angle the
2 mast in relation to the machine.
1
3
005247
1. Tilt cylinder
2. Mast
3. Lower mast anchorage on frame

page
–
See section 10 Common hydraulics , group 10.7.1 Hydraulic cylinders.
7.7.9 Mast
Lift masts, description
page
–
See Lift masts, description page 25.

page
–

7 Load handling – 7.9 Load carrier 63
7.9 Load carrier

7.9.1 Lift forks
Lift forks, description (standard forks)
page
–
007729
Lift fork (Roller fork)

1. Support roller
The lift forks, which lift the load, come in several sizes and designs. All
lift forks are entirely forged in high-strength steel.
002049
Lift fork for the fork shank system (pin type)

1. Bolt
2. Pin
3. Cotter pin
4. Shaft
5. Lift fork
6. Fork mounting

64 7 Load handling – 7.9.2 Carpet boom
Lift forks, description (inverted)

page
–
Inverted lift forks for the fork shank system are used, for example, to-
gether with a top lift attachment to increase lift height. All lift forks are
entirely forged in high-strength steel.
The inverted lift forks are attached to the fork shanks. The forks have
a fixed spacing and cannot be spread like standard lift forks.
2
3
002050
1. Upper retaining hook

2. Lock pin
3. Movable catch
4. Lower retaining hook
7.9.2 Carpet boom

Carpet boom, description
page
–
1
The carpet boom for the fork shank system is used to lift cylindrical
goods.
The carpet boom is attached to both fork mountings.
2
3
002051
4
1. Upper retaining hook
2. Lock pin
3. Movable catch
4. Lower retaining hook

7 Load handling – 7.10 Other functions 65
7.10 Other functions

7.10.5 Separate top lift attachment
Separate top lift attachment, description
page
–
The machine is prepared for connection of a separate top lift attach-

ment. This is lifted with the lift forks, is connected electrically to a con-
tact on the lifting carriage and is connected hydraulically to the
spreading function via quick-couplings located on the lifting carriage.
The side shift and spreading cylinders remain connected to side shift.
007494
The top lift attachment houses a valve that determines whether
spreading 20’-40’, twistlocks or rotation is to be activated. Spreading
20’-40’ and twistlocks are activated with a switch. Rotation is control-
led with the spreading control lever.
For a more detailed description, see:
Spreading 20’-40’, description page 65
Rotation, description page 83
Twistlocks, description page 88
7.10.5.1 Spreading
Spreading 20’-40’, description
page
–
Spreading 20’-40’ is only available if a separate top lift attachment is

fitted. The spreading motor of the attachment is connected to the
spreading section of the load handling control valve instead of the side
shift and spreading cylinders.
007503
Electric servo
Spreading 20’-40’ is activated with the spreading 20’-40’ switch and
the spreading solenoid valves of the load handling control valve when
the switch is activated. The attachment’s changeover valve for spread-
ing, rotation or twistlocks directs the control pressure on to the attach-
ment’s spreader motor.
See Spreading, function description (electric servo) page 52.

66 7 Load handling – 7.10.5.1 Spreading
Spreading 20’-40’, function description (electric servo)

page
–

switch age
Top lift attachment Connected -
D5
D6
5 6 7
D790-1
D797-2
8
D8
3 C2 10 14
A 4 9
2 A1
T H 11 12
P C 13
P2
P1
T B1
15
9
C1
EF
P
1 1 T
009687

sure.
4 The servo filter cleans the oil. - Servo filter, description page 19

7 Load handling – 7.10.5.1 Spreading 67

5 The spreading 20’-40’ switch sends a sig- U = 24 V Section 9 Frame, body, cab and accessories,
nal to the cab control unit (D790-1). group 9.1 Controls and instruments
6 The cab control unit (D790-1) supplies U = 24 V D6: Diagnostic menu, see section 8 Control
voltage to the relay for activating spread- system, group 8.4.5.9 HYD, menu 9
ing 20’-40’ (K3006) and transmits 4th
function in or 4th function out on the CAN
bus.
7 The relay for activate spreading 20’-40’ U = 24 V -
(K3006) supplies voltage to the spread-
ing 20’-40’ relay (K6) on the attachment.
8 The frame option control unit (D797-2) U = 24 V Load handling control valve, description
activates the spreading out solenoid (electric servo) page 68
valve (Y6018) or the spreading in sole- D8: Diagnostic menu, see section 8 Control
noid valve (Y6019) of the load handling system, group 8.4.8.9 ELSERV, menu 9 and
control valve. 8.4.8.10 ELSERV, menu 10
9 The spreading out solenoid valve - Load handling control valve, description
(Y6018) or spreading in solenoid valve (electric servo) page 68
(Y6019) opens and directs servo pres-
sure to the spreading spool in the load
handling control valve, which changes
position and directs pressure to the
changeover valve for twistlocks or
spreading on the attachment.
10 The 20’-40’ spreading relay (K6) is acti- U = 24 V Changeover valve, spreading, rotation or
vated and supplies voltage to the spread- twistlocks, description page 68
ing solenoid valve (Y6046) in the
changeover valve for spreading, rotation
or twistlocks.
11 The spreading solenoid valve (Y6046) - Spreader motor, description page 70
actuates the spreading spool, which
changes position and directs pressure to
the spreader motor.
12 The spreader motor moves the spreader - Spreader chains, description page 73
beams in or out in the attachment’s main Spreader beam, description page 80
beam via the spreader chain.
Attachment main beam, description page 82
13 When the spreader beam approaches its Indicator plate in front of Position sensor spreading, description page
end position, the damping sensor sends sensor: U = 24 V 83
a voltage signal to the damping relay
(K5).
14 The damping relay (K5) is activated and U = 24 V Changeover valve, spreading, rotation or
supplies voltage to the damping solenoid twistlocks, description page 68
valve (Y6046-2) in the changeover valve
for spreading, rotation or twistlocks.


15 The damping solenoid valve (Y6046-2) - Changeover valve, spreading, rotation or
actuates the damping spool, which twistlocks, description page 68
changes position and limits the flow to the
spreader motor.

draulics, Separate top lift attachment

page
–

fixed displacement.
page
–

page
–

page
–
Load handling control valve, description (electric servo)

page
–
If the machine is equipped with a separate top lift attachment, the at-
tachment’s functions are connected to the spreading section of the
load handling control valve. See Spreading 20’-40’, function descrip-
Spreading 20’-40’, rotation and twistlocks on the top lift attachment
use the same pressure feed from the machine. Valves on the attach-
ment handle switching between the functions.
trol valve, description (electric servo) page 21.
Changeover valve, spreading, rotation or twistlocks,

page
–
description
For top lift attachment only

The changeover valve for spreading, rotation or twistlocks in located
in the back edge of the attachment. It directs pressure from the load
handling control valve to the spreader motor, the rotation cylinders or
the twistlock cylinders.
The changeover valve has three valves that are actuated by solenoid
1
valves. The solenoid valves are energised by the frame control unit
007709
(D797-1) though the relay on the attachment upon activation.
1. Changeover valve, spreading, rotation or twistlocks If no valves are activated, the pressure is directed to the rotation cyl-
inders.

Twistlocks
The solenoid valve for blocking twistlocks (Y6044) actuates the twist-
lock valve upon activation so that the pressure is directed to the twist-
lock cylinders. The signal can be checked via the diagnostic menu.
See section 8 Control system, group 8.4.11.3.2 EXT-ATTACH, menu
2.
Spreading
The extension solenoid valve (Y6046) actuates the spreading valve
upon activation, causing pressure to be directed to the spreader mo-
tor. The signal can be checked via the diagnostic menu. See section
8 Control system, group 8.4.11.3.3 EXT-ATTACH, menu 3.
The extension damping solenoid valve (Y6046-2) actuates the damp-
ing valve upon activation so that pressure to the spreader motor is
dampened.
Spreader motor valve block, description

page
–
For top lift attachment only.

The spreader motor valve block regulates the oil’s direction to the
spreader motor. The valve block sits on the spreader motor all the way
out out to the left on the front side of the attachment’s main beam.
The valve block maintains a balance between supply and spreading
speed. Balance means that the valve block prevents the motor from
pumping oil, i.e. rotates faster than the supply of oil allows. The
spreading valve block contains overcenter valves that block the outlet
if pressure on the outlet side is higher than pressure on the inlet side.
I II
001004
Hydraulic diagram, spreader motor valve block

Spreader motor, description

page
–
1
10 Via two chains, the spreader motor moves the spreader beams in and
out in the attachment’s main beam. The spreader motor sits all the way
2 out out to the left on the front side of the attachment’s main beam.
3 The hydraulic motor is integrated with a planetary gear that reduces

9 speed and makes the motor more powerful. A valve block with two
4
8 overcenter valves is located on the hydraulic connections and pre-
7 vents the motor from rotating faster than the supplied hydraulic pres-
6 000650 sure.
5
1. Main beam, attachment
2. Fuse box, attachment
3. Changeover valve, spreading, rotation or twistlocks
4. Spreading position sensor
5. Alignment sensor
6. Twistlock
7. Sensor, twistlocks
8. Lock cylinder, twistlocks
9. Spreader beam
10. Spreader motor
Spreader motor, replacement

page
–
NOTE
Safety.
2 Remove the cover on the left side of the attachment’s main beam.

3 Start the engine and run spreading out until the chain tensioners
are visible in the inspection holes.
Safety.
er.
7 Measure and note the chain tensioners’ length to attain the cor-
rect chain tension when refitting.
8 Slacken the chain tensioner on the engine side and remove the
chain from the tensioner.
9 Remove the protective plate from over the spreader motor.
10 Mark up and detach the hydraulic hoses from the valve block of
the spreader motor.

11 Remove the spreader motor assembly.
12 Transfer the valve block to the new motor assembly.
NOTE
13 Clean the contact surfaces between the planetary gear and the
attachment’s main beam.
14 Fit the motor assembly. Tighten the screws crosswise in stages
with increasing torque until reaching 117 Nm (oiled screw).
15 Attach the hydraulic hoses to the valve block.
16 Connect the spreader chain to the chain tensioner. Check that

the chain runs straight in the hydraulic motor sprocket.
17 Tension the chain tensioner to the same degree as before.
19 Check that the hydraulic connections are sealed tightly.
20 Check that spreading is working.
21 Fit the protective plate over the motor.
22 Brush or spray the spreader chain with chain oil. Make sure the
chain is well lubricated.
23 Fit the cover plates on the attachment’s main beam.

24 Check the oil level in the hydraulic oil tank with the gantry all the
way down and the mast tilted in. The oil level should be in the top
of the level glass. Top up as needed.
CAUTION
Overfilling of oil.

Spreader chains, description

page
–

The spreader chains move the spreader beams in and our of the at-
tachment’s main beam. The power from the spreader motor is trans-
ferred to the spreader beams by two chains, which run inside the
attachment between the spreader beams. Sprockets guide the chain
along its route. The chains are tensioned by adjusting the mounting.
M The chains are fastened crosswise with one end at the bottom of one
spreader beam and the other end along the side of the other spreader
beam.
Openings in the sides of the spreader beams and the attachment’s
main beam make it possible to access the chains for maintenance pur-
poses.
000472
Principle diagram, spreader chains
Spreader chains, checking

page
–
1 Before adjusting, clearance between the slide plates and spread-

er beams must be checked. Otherwise the chain mountings will
be damaged. See Spreader beam, description page 80.
2 Start the engine, run spreading in to the 20-foot position and
switch off the engine.
3 Check the C-C measurement between the twistlocks.
C-C 20 feet: 5853 ±3 mm
Check that both spreader beams are against the 20-foot stop and
that the distance between the spreader beam and spreader mo-
tor mounting is at least 3 mm.

4 If necessary, adjust the distance by moving washers between the

right and left 20-foot stop. Do not change the number of washers.
NOTE
Note the distance the stop was adjusted.
Run spreading out a little to make it possible to move the wash-
ers.
5 Remove the cover plate on the attachment’s main beam.
6 If the 20-foot stop is adjusted, the spreader chains must be adjust

the same amount.
NOTE
Check the vertical position of the chain tensioner so that the
chain runs straight to the sprocket.
7 Start the engine, run spreading out to the 40-foot position and
switch off the engine.
8 Check the C-C measurement between the twistlocks.
C-C 40 feet: 11985 ±3 mm
005105

9 Adjust the 40-foot stop if necessary.

10 Start the engine and run spreading out to the 40-foot position.
11 Wait 2 minutes and then check the tension of the chains.
Measure how much the chain can be pressed in at the hole clos-
est to the centre of the attachment. When the chain is pressed in-
ward with a force of 250 N, it should move 20–40 mm from its
home position.
12 Adjust chain tension if necessary.
Start the engine and run spreading out until the chain tensioners
are visible in the inspection holes. Adjust the chains.
NOTE
Adjust max. 2 mm on the chain tensioner at a time.
005106
13 Repeat steps 9–11 until the chains have the correct tension.
14
If the machine is equipped with a 30 or 35-foot stop, start the en-
gine, run spreading out to the 30 or 35-foot position, switch off the
engine and check the C-C measurement between the twistlocks.
C-C 30 feet: 8918 ±3 mm
C-C 35 feet: 10488 ±3 mm
IMPORTANT
Check the distance at stop from both 20’ and 40’.
chain is well lubricated.
Spreader chain, replacement

page
–
1 Park the machine with the attachment as far down as possible.

2 Remove the cover plate on the attachment’s main beam.

3 Start the engine and run spreading out until the chain tensioners
are visible in the inspection holes.
005105
5 Slacken the chain tensioner of the chain in question and remove

it from the tensioner.
NOTE
Measure and note the chain tensioners’ length to attain the
correct chain tension when refitting.
005105
6 Remove the sprocket of the chain in question.
NOTE
Note the location of the spacer ring.
If the sprocket on the engine side must be removed, fist remove
the spreader motor. See Spreader motor, replacement page 70.

7 Pull the chain out through the sprocket hole so that the chain runs
along the spreader beam.
8 Temporarily fasten the chain along the cable rack to prevent the
chain from being pinched.
9 Pull out the spreader beam.

Use a machine or the like to pull the spreader beam out of the at-
tachment’s main beam. Stop when the spreader beam is close to
the 40-foot stop.
NOTE
Support the spreader beam to minimise breaks. If neces-
sary, remove the upper slide plates to reduce resistance.
10 Remove the boom stop from the attachment’s main beam.

11 Remove the hydraulic hoses’ clamping on the attachment’s main
beam.

12 Detach the cable rack from the attachment’s main beam. Support
the cable rack so that it is not damaged.
13 Pull out the spreader beam until the chain mounting becomes ac-
cessible.
14 Detach the chain from the spreader beam and cable rack.
15 Connect the new chain to the spreader beam.
16 Fasten the chain along the cable rack so that it runs straight along
the spreader beam.
chains is well lubricated.
18 Slide in the spreader beam so that the extension stop can be fit-
ted.
19 Fit the extension stop.
20 Connect the cable rack to the attachment’s main beam.
21 Fit the hydraulic hoses’ clamping on the attachment’s main
beam.
22 Slide in the spreader beam until it is extended the same amount
as the other one. This facilitates fitting of the chains.
23 Detach the chain from the cable rack and insert it through the
sprocket hole.

24 Fit the sprocket. The spacer ring should sit on the underside of
the sprocket.
If the rotation motor has been removed, refit it. See Spreader mo-
tor, replacement page 70.
NOTE
Check that the chain runs straight in the sprockets.
25 Connect the chain to the chain tensioner.
NOTE
Use a new split pin.
005105
26 Lubricate the sprocket bearings with grease.

27 Tension the spreader chain to the same degree as before. Tight-
en the lock nut.
28 If the slide plates have been removed, refit them.
30 Check that spreading is working properly.
31 Stop the engine
32 Check chain tension. See Spreader chains, checking page 73.

Spreader beam, description

page
–
1
10 The spreader beams are the part of the attachment that grips the con-
tainer. Two spreader beams run along the main beam. The spreader
2 beams are slid in and out via the spreader motor and spreader chains.
3 The spreader beam houses twistlocks. See Twistlocks, description

9 page 88.
4
8
7
6 000650
5
5. Alignment sensor
6. Twistlock
9. Spreader beam
10. Spreader motor
Spreader beam slide plates, replacement

page
–

2 Take the strain off the glide plate in question.
The pressure can be relieved from the slide plates by raising the
outer edge of the spreader beam or inserting wedges to alter the
position of the spreader beam in the attachment’s main beam.
The photo depicts the inner slide plates of the attach-

ment’s main beam.

3 Remove the attaching bolts for the glide plate’s bracket.

4 Remove the guide plate’s guide pin.
5 Pull out the glide plate with spacer plate and bracket.
The photo depicts the inner slide plates of the attach-

ment’s main beam.
6 Position the new slide plate.
Check the clearance between the spreader beam and the slide
plate. Clearance should be max. 1 mm with all slide plates fitted.
Use a spacer plate to adjust the clearance.
7 Fit the slide plate bracket and guide screw.
Lubrication
007271
8 Lubricate the sliding surfaces of the attachment with white lubri-

cating paste.
9 Run spreading completely in and out approximately 10 times and
check the spreading function.
10 Wipe away excess lubricating paste at the slide plates and on
sliding surfaces.
11 Try to lift a container and check the spreader beams’ clearance
in the attachment’s main beam.

Attachment main beam, description

page
–
1
10 The main beam comprises equipment for spreading (spreader beams,
spreader motor, slide plates and sensor). The attachment’s main
2 beam also houses valves and electrical equipment for attachment
functions.
3
9 4
8
7
6 000650
5
5. Alignment sensor
6. Twistlock
9. Spreader beam
10. Spreader motor

7 Load handling – 7.10.5.2 Rotation 83
Position sensor spreading, description

page
–
1 2 3 4 5 The spreading position sensors indicate the position of the spreader

beams. The position sensors are used to control spreading so that the
twistlocks fit the container. The position sensors are located under the
protective plate on the top left side of the attachment’s main beam.
The end position sensor (B769-1) indicates the end position of 20 and
40-foot containers. The sensor detects the spreader beam end posi-
tions via two indicator plates on the top of the spreader beams. The
sensor is used to activate damping.
004945
1. Indicator plate 20’

2. Damping sensor 20’ and 40’, Stop 30’
3. Damping sensor 30’
4. Indicator plate 30’ or 35’
5. Indicator plate 40’
Position sensor, checking and adjustment

page
–
See Position sensor, checking and adjustment page 3.
7.10.5.2 Rotation
Rotation, description
page
–
Rotation is only available if a separate top lift attachment is fitted. The

rotation cylinders of the attachment are connected to the spreading
section of the load handling control valve instead of the side shift and
spreading cylinders.
007224
If a top lift attachment is connected, check that its hoses are connected
to the spreading section so that spreading in is rotation clockwise and
spreading out is rotation anticlockwise. See Rotation, function descrip-
tion (electric servo) page 84 for a function description.
For more information, see Spreading, function description (electric
servo) page 52.

84 7 Load handling – 7.10.5.2 Rotation
Rotation, function description (electric servo)

page
–

switch age
Spreading Not activated Spreading 20’-40’, function description (electric servo) page 66
Twistlocks Not activated Twistlocks, function description (electric servo) page 89
5a D5
5b
6
D790-1
D797-2
7
D7
3 C2
8 10
A 4
2 A1 9
T H
P C
P2
P1
T B1
10
8
C1
EF
P
1 1 T
009689

pressure.


5a The control lever (R8074) sends the cab U = 0.5-4.5 V Section 9 Frame, body, cab and accessories,
control unit (D790-1) a voltage signal Right side front: U = <2.5 V group 9.1 Controls and instruments
proportional to lever movement.
Left side front: U = >2.5 V D5: Diagnostic menu, see section 8 Control
for right side front and 4.5
left side front. Voltage low-
er than 0.5 V and higher
than 4.5 V is used to detect
defects in cable harnesses
and controls.
cab control unit (D790-1) a voltage signal Right side front: US815-P4 group 9.1 Controls and instruments
proportional to lever movement. D5: Diagnostic menu, see section 8 Control
= <2.5 V
Left side front: US815-P4 =
>2.5 V
for right side front and 4.5
left side front. Voltage low-
er than 0.5 V and higher
than 4.5 V is used to detect
defects in cable harnesses
and controls.
6 The cab control unit (D790-1) transmits Checked by control sys- Section 11 Common electrics, group 11.5.3.1
spreading in or spreading out on the tem; error indicated with Cab control unit (D790-1)
CAN bus. error code.
7 The frame option control unit (D797-2) U = 24 V Section 11 Common electrics, group 11.5.3.3
activates the spreading in solenoid valve Frame control unit (D797-2)
(Y6019) or the spreading out solenoid D7: Diagnostic menu, see section 8 Control
valve (Y6018). system, group 8.4.8.7 ELSERV, menu 7 and
8 The spreading in solenoid valve (Y6019) - Load handling control valve, description page
or spreading out solenoid valve (Y6018) 86
directs pressure to the spreading spool
in the load handing control valve, which
changes position and pressurises the
changeover valve for spreading, rotation
or twistlocks on the attachment.
9 The changeover valve for spreading, ro- - Changeover valve, spreading, rotation or
tation or twistlocks directs the oil on to twistlocks, description page 68
the rotation cylinders.

86 7 Load handling – 7.10.5.2 Rotation

10 The rotation cylinders rotate the attach- - Rotation cylinders, description page 87
ment main beam in relation to the rota- Rotation carriage, description page 87
tion yoke.
Attachment main beam, description page 82


page
–

fixed displacement.
page
–

page
–

page
–
Load handling control valve, description

page
–
If the machine is equipped with a separate top lift attachment, the at-
tachment’s functions are connected to the spreading section of the
load handling control valve.
Rotation is clockwise during side shift left and anticlockwise during
side shift right.
For more information, see Load handling control valve, description

page
–
description

See Changeover valve, spreading, rotation or twistlocks, description
page 68.

Rotation cylinders, description

page
–
1 2 3 4 3 2 1
The rotation cylinders are housed between the fork pockets and the ro-
tation carriage and rotate the attachment in relation to the mast.
003601
1. Rotation cylinder
2. Catch
3. Fork pocket
4. Slide plate

page
–
Rotation carriage, description

page
–
1 2 3 4 3 2 1
The rotation carriage is the part of the attachment that joins the attach-
ment to the lift forks. the rotation carriage is attached to the lift forks by
two fork pockets. Housed between the rotation carriage and the fork
pockets are slide plates that allow the rotation yoke to rotate in relation
to the lift forks.
003601
2. Catch
3. Fork pocket
4. Slide plate
Attachment main beam, description

page
–
See Attachment main beam, description page 82.

page
–

88 7 Load handling – 7.10.5.3 Twistlocks
7.10.5.3 Twistlocks
Twistlocks, description
page
–
Twistlocks are only available if a separate top lift attachment is fitted.

The lock cylinders of the attachment are connected to the spreading
section of the load handling control valve instead of the side shift and
007502
Twistlocks secure the container to the attachment. Twistlocks are
maneuvered with hydraulic cylinders that are controlled by the load
handling control valve.
The twistlock function is found in the following versions:
Electric servo
Twistlock is activated with the twistlock switch and the spreading sole-
noid valves of the load handling control valve when the switch is acti-
vated. The attachment’s changeover valve for spreading, rotation or
twistlocks directs the control pressure on to the attachment’s lock cyl-
inders. See Twistlocks, function description (electric servo) page 89.

7 Load handling – 7.10.5.3 Twistlocks 89
Twistlocks, function description (electric servo)

page
–

switch age
Spreading Not activated Spreading 20’-40’, function description (electric servo) page 66
D5
5
12, 22 6 20 10 20
D790-2 D790-1
D797-2
13 ,11, 21
D6
7
15
D13
3 C2 18 18
17 D19 8
A 4 14
2 A
T H
19
P C
P2 9
16 17 19
P1
T B
14 D9
18 18
C1
EF
P
1 1 T
009691

1 The hydraulic oil pumps pump oil from the See pressure plate on left Section 10 Common hydraulics , group
hydraulic oil tank. frame beam. 10.4.3 Vane pump with fixed displacement
sure.


5 The switch for locking the twistlocks - Section 9 Frame, body, cab and accesso-
(S1003) (automatic mode) sends a voltage ries , group 9.1 Controls and instruments
signal to the cab control unit (D790-1). D5: Diagnostic menu, see section 8 Control
system, group 8.4.11.3 EXT-ATTACH,
menu 1
6 The cab control unit (D790-1) supplies volt- U = 24 V D6: Diagnostic menu, see section 8 Control
age to the relay for activating twistlocks system, group 8.4.11.3 EXT-ATTACH,
(K3005) and transmits 4th function in or 4th menu 6
function out on the CAN bus.
7 The activate twistlocks relay (K3005) sup- U = 24 V -
plies voltage to the twistlock relay (K7) on
the attachment.
8 The alignment sensors (B7202L/R and Full contact: Sensor alignment, description page 96
B7203L/R) (the four sensors are connect- U = 24 V
ed in series) send a voltage signal to the
No contact for one or
alignment relay (K1) once all four sensors
more sensors:
indicate contact.
U=0V
9 The alignment relay (K1) is activated and U = 0 V D9: Diagnostic menu, see section 8 Control
grounds the twistlocks relay (K7), the align- system, group 8.4.11.3 EXT-ATTACH,
ment indicator lamp (E564) and the frame menu 4
10 The alignment indicator lamp (E564) on U = 24 V Section 9 Frame, body, cab and accesso-
the attachment illuminates. ries , group 9.1 Controls and instruments
11 The frame option control unit (D797-2) Checked by control sys- Section 11 Common electrics, group
transmits alignment on the CAN bus. tem, error shown with er- 11.5.3.3 Frame control unit (D797-2)
ror code.
12 The KIT control unit (D790-2) illuminates - Section 9 Frame, body, cab and accesso-
the alignment indicator lamp on the cab ries , group 9.1 Controls and instruments
lamp panel.
13 The frame option control unit (D797-2) ac- U = 24 V Load handling control valve, description
tivates the spreading out solenoid valve page 92
(Y6018) or the spreading in solenoid valve D13: Diagnostic menu, see section 8 Con-
(Y6019). trol system, group 8.4.11.3 EXT-ATTACH,
menu 3


14 The spreading out solenoid valve (Y6018) - Load handling control valve, description
or spreading in solenoid valve (Y6019) page 92
opens and directs servo pressure to the
spreading spool in the load handling con-
trol valve while the spreading spool in load
handling control valve changes position
and directs pressure to the changeover
valve for twistlocks or spreading.
15 The twistlocks relay (K7) energises the U = 24 V -
twistlocks solenoid valve (Y6044) in the
changeover valve for spreading or twist-
locks.
16 The twistlock solenoid valve (Y6044) actu- - Changeover valve, spreading, rotation or
ates the twistlock spool, which changes twistlocks, description page 68
position and directs pressure to the lock
cylinders.
17 The lock cylinders rotate the twistlocks. - Lock cylinder, description page 93
Lock mechanism, description page 93
18 Locked twistlocks: Sensor directly opposite Sensor twistlocks, description page 97
The locked twistlocks sensor (B7205L/R) indicator plate: U = 24 V
(the two sensors are connected in series)
sends voltage to the locked twistlocks relay
(K4).
Unlocked twistlocks:
The unlocked twistlocks sensor (B7204L/
R) (the two sensors are connected in se-
ries) sends voltage to the unlocked twist-
locks relay (K3).
19 Locked twistlocks: U=0V D19: Diagnostic menu, see section 8 Con-
The locked twistlocks relay (K4) is activat- trol system, group 8.4.11.3 EXT-ATTACH,
ed and grounds the locked twistlocks indi- menu 5
cator lamp (E563) and the frame control
unit (D797-1).
The unlocked twistlocks relay (K3) is acti-
vated and grounds the unlocked twistlocks
indicator lamp (E562) and the frame con-
trol unit (D797-1).
20 Locked twistlocks: U = 24 V Section 9 Frame, body, cab and accesso-
The locked twistlocks indicator lamp ries , group 9.1 Controls and instruments
(E563) on the attachment illuminates.
The unlocked twistlocks indicator lamp
(E562) on the attachment illuminates.


21 The frame option control unit (D797-2) Checked by control sys- Section 11 Common electrics, group
transmits twistlock status on the CAN bus. tem, error shown with er- 11.5.3.3 Frame control unit (D797-2)
ror code.
22 The KIT control unit (D790-2) activates the - Section 9 Frame, body, cab and accesso-
unlocked/locked twistlocks indicator lamp ries , group 9.1 Controls and instruments
(E562/E563) on the cab lamp panel.


page
–

fixed displacement.
page
–

page
–

page
–
Load handling control valve, description

page
–
When a top lift attachment is connected, the twistlocks on the attach-

ment are connected to the load handling control valve instead of the
Twistlocks and spreading 20’-40’ on the top lift attachment use the
same pressure feed from the machine. An electrically controlled valve
on the attachment is used to switch between functions (twistlock and
spreading 20’-40’).
Spreading in is lock twistlocks and spreading out is open twistlocks.
For more information, see Load handling control valve, description

page
–
description

See Changeover valve, spreading, rotation or twistlocks, description
page 68.

Lock cylinder, description

page
–
1 2 1 3
The lock cylinder pulls the lock mechanism so that the twistlocks are
rotated. Two lock cylinders - one in the right and one in the left spread-
er beam - pull the lock mechanism. The lock cylinders are located in
the centre of the spreader beam’s longitudinal section.
000635
1. Alignment sensor
2. Lock mechanism
3. Lock cylinder

page
–
Lock mechanism, description

page
–
1 2 1 3
The lock mechanism transfers the force of the lock cylinders to the
twistlocks. Two lock mechanisms - one in the right and one in the left
spreader beam - actuate the twistlocks. The lock mechanism runs
along the longitudinal section of the spreader beam between the twist-
locks.
000635
The lock mechanism consists of a rod with two spherical plain bear-
ings in the end. The rod is fastened in levers that rotate the twistlocks.
1. Alignment sensor
A retaining lug for the lock cylinder sits in the centre of the rod.
2. Lock mechanism
3. Lock cylinder

Twistlocks, description
page
–
1
WARNING
2
Dropped load.
5
Fatal danger!
Twistlocks hold the load during load handling and

therefore it is very important that twistlocks are
4 checked according to instructions and are replaced at
the slightest sign of damage or wear.
000633
3
Twistlocks secure the load and are located in the corners of the
1. Lock mechanism
spreader beam’s longitudinal part.
2. Attachment sensor
3. Alignment pin Twistlocks are manufactured from high-strength steel according to in-
4. Lift pin ternational standards. The lift pins are marked with serial numbers.
5. Lock guide Twistlocks are connected in pairs via a linkage system to a hydraulic
cylinder which in turn is controlled via a section in the attachment’s
control valve. Inductive sensors send signals when the twistlocks are
locked and unlocked, respectively.

Twistlock, replacement
page
–

2 Depressurise the brake and hydraulic systems. See section B
Safety.
3 Clean the twistlocks and the surrounding area.
4 Detach the centre nut of the twistlocks.
5 Tap on the nut so that the lift pin releases from the wedge.
6 Hold the lift pin while removing the centre nut.
WARNING
Dropped component.
Risk of pinch injury or product damage.
Twistlock weighs approx. 30 kg.
7 Remove the centre nut and lift away the twistlock.

8 Coat a new lift pin with EP2 universal grease and position it in the
guide pin.
9 Place the lift pin and guide pin in the spreader beam. Place the
guide pin so that the grease cup is accessible through the holes
in the spreader beam.
NOTE
Do not forget the washer between the spreader beam and
guide pin.
10 Position the wedge, bearing, lever, new locking washers and

new lock nuts on the lock pin.
Coat the components with EP2 universal grease before fitting.
11 Check the positions of the parts and that the twistlock can move.
12 Tighten the lock nut to 300 Nm (oiled screw).
13 Lubricate the guide pin, lever and bearing arrangement with EP2
universal grease.
14 Check that the twistlock mechanism can move.
15 Turn on the power supply and start the machine.
16 Check that the twistlock is working.

Sensor alignment, description

page
–

The alignment sensors (B7202L, B7202R, B7203L and B7203R) de-
tect when the attachment has contact with the container. Four induc-
tive sensors - one at each twistlock at the far corner of the longitudinal
section of the spreader beam - are used to indicate alignment.
The sensor senses the position of a spring pin which is pressed in
when the attachment has contact up against the container. The sensor
000634
is located above the pin. The position of the sensor can be adjusted so
that it gives a signal when the pin is pressed in and the head is level
with the lower edge of the spreader beam. The clearance between the
attachment and the container’s corner boxes means the sensors stop
sending signals when the attachment is lifted.
The sensors are connected in series, with the first sensor supplied
voltage by the frame control unit (D797-1). The sensor sends voltage
on to the next sensor when the indicator pin is depressed. Once all
sensors indicate contact, the last sensor sends voltage to the align-
ment relay (K1). When the alignment relay (K1) is activated, it supplies
voltage to the alignment indicator lamp (E564) and sends a voltage
signal to the frame control unit (D797-1).
Alignment sensor, checking

page
–

2 Check that the indicator pins in the corner boxes can freely move
up and down. The indicator pins must spring down when they are
not loaded.
3 Check that the sensor is free of damage and dirt.
4 Start the machine.
5 Lower the attachment to a container and check that all twistlocks

indicate contact - filled circles in the alignment event menu - and
that the alignment indicator lamp illuminates.
6 Lift the attachment slightly so that contact is just broken (unfilled
circles in the alignment event menu or alignment indicator lamp
000360
goes out).
Event menu, alignment 7 Check more must indicator pin movement is required to detect
contact. The movement must be 3–4 mm.
8 Adjust sensor position if necessary. See Position sensor, check-
ing and adjustment page 3.
Position sensor, checking and adjustment

page
–
See Position sensor, checking and adjustment page 3.

Sensor twistlocks, description

page
–
1 2 1 3
Twistlocks sensors (B7204L, B7204R, B7205L and B7205R) detects
when the twistlocks are locked or unlocked. Four inductive position
sensors - two in each spreader beam - detect the position of the lock
mechanism. The sensors sit at the lock cylinder in the centre of the
longitudinal section of the spreader beam.
000635
Both sides function the same way independently of one another. An
indicator plate sits on the lock mechanism at the lock cylinder. When
1. Twistlocks sensor
the lock mechanism is in the position that locks the twistlocks, one of
2. Lock mechanism
the sensors sends a signal to the attachment control unit (D791-1).
3. Lock cylinder
When the lock mechanism is in the position that unlocks the twistlocks,
the other sensor sends a signal to the attachment control unit (D791-
1). No signals are sent if the lock mechanism stops midway.

page
–


8 Control system 1
8 Control system
Table of Contents 8 Control system

mm mm mm mm mm mm
8 Control system ............................................................................................... 3

8.1.10 Error code menu .................................................................................... 4
8.2 Monitoring ................................................................................................... 7
8.2.1 Overload protection ............................................................................... 7
8.2.2 Bypass ................................................................................................... 7
8.2.3 Speed limitation ..................................................................................... 7
8.2.4 Service indicator .................................................................................... 8
8.4 Diagnostics ................................................................................................. 9
8.4.1 CAN/POWER ....................................................................................... 11
8.4.2 LIGHTS ................................................................................................ 25
8.4.3 CAB ..................................................................................................... 36
8.4.4 CLIMATE ............................................................................................. 44
8.4.5 HYD ..................................................................................................... 50
8.4.6 ENGINE ............................................................................................... 57
8.4.7 TRANSM .............................................................................................. 64
8.4.8 ELSERV ............................................................................................... 76
8.4.9 ATTACH, DCF360-450CSG ................................................................ 89
8.4.9 ATTACH, DCF 90-100 with lifting hook attachment .......................... 104
8.4.9 ATTACH, DCF 90-100 with twistlock attachment .............................. 120
8.4.10 OLS .................................................................................................... 134
8.4.11 EXTRA ............................................................................................... 136
8.5 Settings .................................................................................................. 166
8.5.1 Initiation ............................................................................................. 166
8.5.2 Calibration .......................................................................................... 201
Workshop smanual DCF 280-500 VDCF02.02GB

2 8 Control system
VDCF02.02GB Workshop smanual DCF 280-500

8 Control system – 8 Control system 3
8 Control system
mm mm mm mm mm mm
Control system, general

page
–
The machine’s functions are electrically controlled in many cases. The

signals which control the machine are monitored to warn the operator
or limit the machine’s functions in certain dangerous situations or if
faults arise in the machine.
The control system function is divided into the following functions:
• Monitoring
• Error codes
• Diagnostics
• Settings
• Software
Monitoring functions describes the machine’s monitoring functions
that warn the operator or limit the machine’s functions in the event of
any dangerous situations.
Error codes notify operators and mechanics when malfunctions have
been detected.
Diagnostic test is tool for performing service and troubleshooting with
menus in the machine’s display.
Settings is the tool for setting and adapting the machine’s functions.
The software creates the functions in the control system.

4 8 Control system – 8.1 Controls and instruments

8.1.10 Error code menu
Error code menu, description
page
–
The control system’s display is divided into four fields that show infor-
C mation (see figure to the left).
D E • Field B: Error code level shown with a symbol.

• Field C: Indicates error code.
B
000389
• Field D: Indicates type of error.
• Field E: Indicates which function is affected by error code.
• The book symbol means that there's information in the operator's
manual.
Field B: Error code level

The control system gives error code information in three levels which
are indicated with a symbol in the lower left corner (B) on the display
unit.
• Stop
C Indicates a serious malfunction that may affect operator safety or
cause machine breakdown. The error code must be taken care of
D E
immediately. Stop working with the machine and contact service
immediately.
000350
The error code is shown automatically on the display.
• Warning
C Indicates machine malfunction that should be taken care of as
soon as possible. After finished work shift with the machine, con-
D E
tact service as soon as possible.
000351
• Information
C Information to the operator that something should be taken care
of as soon as possible, e.g., defective light bulb. Take action to fix
D E the cause of the error code as soon as possible.
The error code is stored in the error code list under operating
000352
menu for service.
Field C: Error code number

The control system gives error codes from three sub-systems:
• Machine:
C
Shown with error code number XXX on display.
D E
B
000389

8 Control system – 8.1.10 Error code menu 5
• Engine:
C Shown with error code number XXX/YY on display.
D
NOTE
B If several error codes come from the engine, the error code
001343
level is shown for the most serious error code.
• Transmission:
C Shown with error code number XX/YY on display.
B
001344
Field D: Type of error

1. Too high/too low temperature.
1 2 3
2. Incorrect signal to solenoid valve.
3. Incorrect hydraulic pressure.
4. Incorrect sensor signal.
4 5 6 5. Incorrect signal from control.

6. Incorrect signal from battery.
7. Incorrect signal from spool.
8. Level too high/low
7 8 9 9. Incorrect signal to bulb.
10. Incorrect signal, for example, open circuit.
11. Incorrect signal to engine.
10 11
002058

6 8 Control system – 8.1.10 Error code menu
Field E: Affected function

1. Attachment
1 2 3
2. Rotation of attachment
3. Side shift of attachment
4. Length adjustment attachment
4 5 6
5. Leveling attachment
6. Twistlocks
7. Forks up/down
7 8 9 8. Tilt forks
9. Side shift forks
10. Spreading forks
10 11 12 11. Rotation forks

12. Overload protection
13. Hydraulic functions
14. Brake system
13 14 15
15. Steering
16. Engine
17. Transmission
16 17 18
18. Central lubrication
19. Control unit
20. Hardware-related error
19 20 21 21. Cab
22. Air conditioning system
23. Fuel system
22 23 24 24. Headlights
25. Windshield wipers
26. Battery voltage
25 26 27 27. Bulb for lighting
010153

8 Control system – 8.2 Monitoring 7
8.2 Monitoring
8.2.1 Overload protection
Overload protection, description
page
–
Not used.
8.2.2 Bypass
Bypassing, description
page
–
Bypassing is activated with the bypass switch.

Bypassing the safety system makes the following possible:
• locking and opening twistlocks without full alignment
• spread 20’-40’ with locked twistlocks
• lowering a load with alignment on top lift
• manual control of the recirculation damper for ECC or EHC
• release of parking brake in the event of parking brake switch mal-
function
• output signal to solenoid valves with active error codes
• engagement of a gear without the operator in the operator’s seat
- the machine can only move at reduced speed
DANGER
Bypassing the safety systems results in a risk of tip-
ping. Use at your own risk.
8.2.3 Speed limitation

Speed limitation, description
page
–
Speed limitation prevents the machine’s speed from exceeding pre-

set value by limiting gear position and engine rpm.
Machine speed is limited when:
• the control switch is activated.
• the cab is tilted.
• load is not in transport position during transport. Maximum speed
is 5 km/h .
• the reversible operator’s seat is not in position.
• constant speed limitation is set.
Speed limitation is set via the initiation menu; see section 8 Control
system, group 8.5.1.4 INIT DRIVE-TRAIN, menu 9.

8 8 Control system – 8.2.4 Service indicator
8.2.4 Service indicator

Service indicator, resetting
page
–

2 First navigate to the service menu and press Enter.
000056
3 Enter the code for service indicator reset.

Code is obtained from Kalmar Industries Support.
1 23
4 5 NOTE
000060
The code determines which service menu shall be activated

(Service, Diagnostics, Initiation or Calibration).
4 Reset the service indicator by pressing Enter. NEXT SERVICE is
SERVICE INTERVALL changed to indicated interval.
NEXT SERVICE XXXXh
SERVICE INTERVALL To change duration of the service interval, set the desired interval
STORED XXXXh with the plus or minus key.
004908
PRESENT XXXXh

8 Control system – 8.4 Diagnostics 9
8.4 Diagnostics
Diagnostic test, general
page
–
The machine has built-in functions for troubleshooting called diagnos-

DIAGNOSIS tic test. The diagnostic test consists of several menus shown on the
CAN/POWER LIGHTS CAB display. The menus are grouped for faster access. The following pag-
CLIMATE HYD ENGINE
es describe the menu figures content and which functions that can be
TRANSM ELSERV ATTACH
controlled.
005263
OLS EXTRA
The diagnostic test is divided into the following groups:
• Voltage feed and communication for the Control system, CAN/
POWER, description page 11.
• Lighting, LIGHTS, description page 25.
• Cab functions, CAB, description page 36.
• Air conditioning, CLIMATE, description page 44.
• Hydraulic functions, HYD, description page 50.
• Engine, ENGINE, description page 57.
• Transmission, TRANSM, description page 64.
• Functions for electric servo, ELSERV, description page 76.
• Attachment functions, ATTACH, description page 89.
• Overload protection, OLS, description page 134.
• Optional functions, EXTRA, description page 136.
– Reversible operator’s seat, VBFS, menu 1 page 136.
– Mini-wheel or lever steering, EL-STEERING, menu 1 page
144.
– External attachment, EXT-ATTACH, menu 1 page 148.
– Freelift, FREELIFT, menu 1 page 153.
– Tiltable cab and sliding cab, MOVE-CAB, menu 1 page 153.
– RMI, RMI, menu 1 page 163.

10 8 Control system – 8.4 Diagnostics
Diagnostic menu, description

page
–
Diagnostic tests show how the control units interpret input signals as
1 2 3 4
well as which signals that the control units send.
7 DIAG CAB 2(X)

FRONT WIPER
SWITCH (1-3) 2
6 OUTPUT 11 5
008873
FEEDBACK 0
1. DIAG = Diagnostic menus

2. Menu group
3. Menu number
4. Total number of menus in the loop. The number of
menus depends on machine configuration, so the
number of menus is specified as (X) in this manual.
5. Signal value
6. Variable
7. Menu heading
DIAG Indicates that diagnostic tests are selected.
CAB Indicates which menu group is selected, these groups are:

CAN/POWER, description page 11.
LIGHTS, description page 25.
CAB, description page 36.
CLIMATE, description page 44.
HYD, description page 50.
ENGINE, description page 57.
TRANSM, description page 64.
ELSERV, description page 76.
ATTACH, description page 89.
OLS, description page 134.
EXTRA, description page 136.
2 Number of current menu. Every menu group consists of several menus in a loop.
(X) Total number of menus in the group. The number of menus depends on machine configuration, so the
number of menus is specified as (X) in this manual.
Variable The signal that is measured. Different signals are designated in different ways:
SWITCH: a digital input signal, e.g., a switch.
OUTPUT: a digital output signal, e.g., feed to a motor.
INPUT: an analogue input signal, e.g., from a sensor.
REFERENCE: status for an analogue output signal.
REQUIRED: output signal for a control current
FEEDBACK: either feedback signal from a motor or measured current on the minus side for an analogue
output signal.

8 Control system – 8.4.1 CAN/POWER 11
Signal value Measurement value or status for signal for variable. On the same row there are different types that are
interpreted in different ways.
SWITCH: 1 or 0 where 1 means closed circuit.
OUTPUT: two characters where the first number is 1 if the output signal is active. The second number is
status for the circuit, 1=circuit OK, 0=open circuit or short-circuiting.
INPUT: numerical value corresponding to the signal.
REFERENCE: two characters where the first number is 1 if the input signal is active. The second number
is status for the circuit, 1=circuit OK, 0=open circuit or short-circuiting.
REQUIRED: numerical value corresponding to the signal.
FEEDBACK: numerical value corresponding to the signal.
Menu heading Description of the function for which the menu reads signals.
8.4.1 CAN/POWER
CAN/POWER, description
page
–
This group handles redundant power supply to control units and CAN
DIAGNOSIS bus communication.
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE Confirm selection with function key for Enter.
005263
OLS EXTRA
8.4.1.1 CAN/POWER, menu 1

PRESENT REDCAN STATUS, COMMUNICATION MODE
page
–
Description: Indicates communications status for the redundant CAN-

DIAG CAN/POWER 1(X) bus.
PRESENT REDCAN STATUS
COMMUNICATION MODE X Circuit diagram: 11.6-1
NUMBERS OF UNITS X Connection: -
005266
SEGMENT ERROR X
Function: 11.6.2 Redundant CAN-bus
Signal value:
3 Ok.
2 Segment check
0 Error.
PRESENT REDCAN STATUS, NUMBER OF UNITS

page
–
Description: Indicates number of control units, excluding cab KCU

control unit (D790-1), which should be present on the machine in
question. The number depends on the options present.
Circuit diagram: Circuit 11.6-1
Connection: -
Signal value:

12 8 Control system – 8.4.1.2 CAN/POWER, menu 2
X Number of nodes that should be in the machine. Number of

nodes dependent on installed options.
PRESENT REDCAN STATUS, SEGMENT ERROR

page
–
Description: Indicates if there is open circuit on the redundant CAN

bus. And if there is, where the first open circuit is. If there is open cir-
cuit, it is indicated with a number that corresponds to the incorrect seg-
ment on the redundant CAN bus.
Connection: -
Signal value:
0 No open circuit.
>0 If X is separated from 0, the first segment is indicated

as missing contact. A 1 means that the first segment is
incorrect, that is, that contact between first and second
control unit is cut off.
To see which control units are installed on the machine
along with their order, use diagnostic menu CAN/POW-
ER, menu 2, see PRESENT REDCAN STATUS, CON-
NECTED CITIES page 12.

PRESENT REDCAN STATUS, CONNECTED CITIES
page
–
Description: Indicates which control units have contact with the cab
DIAG CAN/POWER 2(X) control unit (D790-1) via the redundant CAN bus. Note that certain
PRESENT REDCAN STATUS control units are optional and may not be installed on the machine.
CONNECTED CITIES
D797-1 D797-2 XX Circuit diagram: 11.6-1, 11.6-2B, 11.6-2C
005267
D795 D791-1 XX Connection:

D795: K1:10, K1:11, K1:12 and K1:13
D797-1, D797-2, D791-1: K2:2, K2:3, K2:4 and K2:5
Function: 11.5.3.2 Frame control unit (D797-1), 11.5.3.3 Frame con-
trol unit (D797-2), 11.5.3.5 Attachment control unit, 11.5.3.12 KID con-
trol unit, 11.6.2 Redundant CAN bus.
Signal value:
1 Communication with the node is OK.
0 No communication and/or there is some node error.

8 Control system – 8.4.1.3 CAN/POWER, menu 3 13

PRESENT OPTION KDU
page
–
Description: Indicates which optional control units should be present

DIAG CAN/POWER 3(X) on the machine and if they have working communication with the cab
PRESENT OPTION KDU KCU control unit (D790-1).
KDU D797-2 XY Circuit diagram: Circuit 11.6-1
007183
KDU D791-1 XY Connection: -
Signal value:
00 The control unit is not installed on the machine.
10 The control unit is installed on the machine but there is no

communication with the cab control unit (D790-1).
11 The control unit is installed on the machine and there is com-

munication with the cab control unit (D790-1).

PRESENT DRIVE-TRAIN CAN BUS STATUS, ENGINE
page
–
Description: Indicates status for engine in drivetrain’s CAN bus.

DIAG CAN/POWER 4(X) Circuit diagram: Engine circuit group 1.0, CAN bus circuit group 11.6
PRESENT DRIVE-TRAIN
CAN BUS STATUS Connection:
ENGINE X Volvo TAD760VE: CAN J1939 from D790-1/K13:1 and K13:2 to
005269
TRANSMISSION X
D794/1 and 2
Volvo TAD950VE: CAN J1939 from D790-1/K13:1 and K13:2 to
D794/1 and 2
Volvo TAD1250VE: CAN J1939 from D790-1/K13:1 and K13:2 to
D794/1 and 2
Cummins QSM11: CAN J1939 from D790-1/K13:1 and K13:2 to
D794/46 and 37
Cummins QSB6.7: CAN J1939 from D790-1/K13:1 and K13:2 to
D794/46 and 37
Function: 11.6.3 Communication
Signal value:
NOTE
The cable harness for CAN bus drivetrain is common to the en-
gine and transmission from the cab electronic box to the frame
electronic box. The cable branches in the frame electronic box. If
communication with both the engine and transmission is cut off,
start troubleshooting at the cable harness between the cab elec-

tronic box and the frame electronic box. If there is communication

(either engine or transmission), this rules out a fault in the cable
harness between the cab electronic box and the frame electronic
box.
PRESENT DRIVE-TRAIN CAN BUS STATUS,

page
–
TRANSMISSION
Description: Indicates status for transmission in drivetrain’s CAN bus.
Circuit diagram: Transmission circuit group 2.0, CAN bus circuit group
11.6
Connection: CAN J1939 from D790-1/K13:1 and K13:2 to D793/L2
and M2
Function: 11.6.3 Communication
Signal value:
NOTE
The cable harness for CAN bus drivetrain is common to the en-
gine and transmission from the cab electronic box to the frame
electronic box. The cable branches in the frame electronic box. If
communication with both the engine and transmission is cut off,
start troubleshooting at the cable harness between the cab elec-
tronic box and the frame electronic box. If there is communication
(either engine or transmission), this rules out a fault in the cable
harness between the cab electronic box and the frame electronic
box.

IGNITION, KEY IN
page
–
Description: Indicates if ignition is on (key in ignition).

DIAG CAN/POWER 5(X)
IGNITION
KEY IN X Connection: signal from S150/15 to digital in D790-1/K11:1
RELAY K315-1 XY
Function: 11.5.1.3 Ignition voltage
007126
RELAY K315-2 XY
Signal value:
1 Input signal active.
0 No signal.

IGNITION, RELAY K315-1

page
–
Description: Control current to Relay ignition voltage (K315-1), 15-volt-

age.
Connection: output signal from D790-1/K10:10 to K315-1
Function: 11.5.1.3 Ignition voltage (15)
Signal value:
00 No output signal, open circuit in circuit.
01 No output signal, circuit OK or short-circuiting. Short-circuiting

can only be detected when the output signal is active.
10 Output signal active, short-circuiting.
11 Output signal active, circuit OK or open circuit. Open circuit

IGNITION, RELAY K315-2

page
–
Description: Control current to Relay ignition voltage (K315-2), 15-volt-

age.
Connection: output signal from D790-1/K10:16 to K315-2
Signal value:



EMERGENCY STOP, SW
page
–
Description: Indicates if switch, control switch, is activated.

DIAG CAN/POWER 6(X)
Circuit diagram: sheet 11.5-6
EMERGENCY STOP, SW X
RELAY K3009-1 XY Connection: signal from S250/2 to digital in D790-1/K8:4
FEEDBACK X
Function: 11.5.1.4 Control switch voltage (15E)
007127
RELAY K3009-2 XY
Signal value:
0 No signal.

EMERGENCY STOP, RELAY K3009-1

page
–
Description: Status for control current to relay K3009-1, for emergency

stop switch voltage, 15E voltage.
Connection: signal from D790-1/K10:11 to K3009-1/86
Signal value:


EMERGENCY STOP, FEEDBACK

page
–
Description: Feedback signal from emergency stop switch voltage re-

lay (K3009-1); indicates that relay is working normally.
Connection: signal from K3009-1/87 via F58-3/8 to digital in D790-1/
K11:13
Signal value:
0 No signal.
EMERGENCY STOP, RELAY K3009-2

page
–
Description: Status of control current to emergency stop switch volt-

age relay (K3009-2), 15E-voltage.
Connection: signal from D790-1/K10:12 to K3009-2/86
Signal value:




790-1 CAB, POWER
page
–
Description: Ignition voltage (15) to cab control unit (D790-1).

DIAG CAN/POWER 7(X)
790-1 CAB
POWER XX.XXV Connection: 15-voltage from K315-1/87 via F54/4 and F58-5/1 to
5V REF X.XXV D790-1/K1:2, D790-1/K1:3 and D790-1/K1:4
005271
Function: 11.5.1 Voltage feed
Signal value: XX.XXV = voltage on the connection. The signal value
should be 22-30 V (battery voltage).
790-1 CAB, 5V REF

page
–
Description: Reference voltage 5 V to controls in cab.

Circuit diagram: Circuits 9.4-1, 9.4-2 and 9.3-3 (contact 1, 2), Circuit
1.0-1 (contact 3), Circuit 7.0-1 (contact 4), Circuit 5.2-1 (contact 5)
Connection:
1. signal from digital out D790-1/K4:5 to Y672/10 and Y673/10
2. signal from digital out D790-1/K5:11 to S118/1, S 139/1 and S117/
1
3. signal from digital out D790-1/K5:13 till B690-1/1 and B690-2/1
4. signal from digital out D790-1/K7:2 to R8071/1, R8072/1, R8073/
1, R8074/1, R8075-1/1 and R8075-2/1
5. signal from digital out D790-1/K9:7 to R825-1/1 and R825-2/1
Function: 9.4 Heating, ventilation and air conditioning (contact 1 and
2); 1 Engine and 2 Transmission (contact 3); 7 Load handling (contact
4); 5 Steering (contact 5)
Signal value: X.XXV = 5.00 V, Important that the signal value is stable
(not varying).

790-1 CAB, 24V SENSOR SUPPLY
page
–
Description: 24 V voltage feed to components in cab.

DIAG CAN/POWER 8(X)
Circuit diagram:
790-1 CAB
24V SENSOR SUPPLY XY 1. Circuit 9.5-1
24V SUPPLY,RPM>500 XY
2. Circuits 2.0-1, 9.1-1, 9.3-1, 9.6-1, 9.6-2, 9.6-3, 9.6-4 and 9.5-1
005275
3. -
4. -
5. Circuits 4.0-1, 7.5-1, 7.9-1, 8.2-1, 9.1-1, 9.3-3, 9.10-1 and 11.5-6
6. Circuit 5-2_1
7. -
8. Circuit 9.7-1
9. Circuit 9.5-1
10. Circuit 9.5-1

Connection:
1. signal from digital out D790-1/K4:14 to M650-1/53a
2. signal from digital out D790-1/K5:1 to S100/5, S110/5, S105-1/5,
S105-2/5, S105-3/5, S143/5, S199-1/5, S199-3/5, S199-4/5,
S220-1/1
3. signal from digital out D790-1/K6.13 not connected
4. signal from digital out D790-1/K7:12 not connected
5. signal from digital out D790-1/K8:16 to S107/5, S169/3, S199-2/5,
S250/1, S1002/2, S1003/3, S1004/5, S1005/5, S1010/3, S1012/
3, S1037/5
6. signal from digital out D790-1/K9:1 to S113/5, S149-2/5, S160-2/3
7. signal from digital out D790-1/K10:1 not connected
8. signal from digital out D790-1/K11:12 to S230/2
Function:
1. 9.5.5 Wiper motor front
2. 2.0 Transmission, 9.3 Seat, 9.6 Lighting
3. -
4. -
5. 11.5.1.4 Emergency stop switch voltage; 4.5 Parking brake sys-
tem; 8.2.2 Bypassing; 9.10.4 Tiltable cab/Hydraulic sliding cab;
7.5 Spreading; 7.8 Levelling; 7.9.1 Twistlocks
6. 5 Steering
7. -
8. 9.3.14 Sensor operator in seat
9. 9.5.7 Wiper motor rear
10. 9.5.6 Wiper motor roof
Signal value:
01 No output signal. Error detection only possible when output

signal is active.
10 Output signal active, short-circuiting or open circuit.
11 Output signal active, circuit OK or open circuit.

790-1 CAB, 24V SUPPLY, RPM >500

page
–
Description: Voltage feed at engine speed higher than 500 rpm.

Connection: signal from digital out D790-1/K10:9 to P708/+ and K358/
86
Function: 9.3.6 Compressor air-suspension seat, 11.1.1 Hour meter
Signal value:



795 DISPLAY, RED. POWER
page
–
Description: Redundant voltage to KID control unit (D795).

DIAG CAN/POWER 9(X)
795 DISPLAY
Connection:
RED.POWER LE X RI X
Le: redundant feed to D790/K1:8
005276
Ri: redundant feed to D790/K1:7

Function: 11.5.1.2 Redundant voltage feed of control units
Signal value:
1 Feed active.
0 No feed.


797-1 FRAME, POWER
page
–
Description: Ignition voltage (15) to frame control unit (D797-1).

DIAG CAN/POWER 10(X)
797-1 FRAME
POWER XX.XXV Connection: 15 voltage from K315-1/87 via F54/4 and F58-2/1 to
RED.POWER LE X RI X D797-1/K2:1, D797-1/K2:9 and D797-1/K2:10
005277
POWER 2 X
Signal value: XX.XXV = voltage on connection. The signal value
797-1 FRAME, RED. POWER

page
–
Description: Redundant voltage to frame control unit (D797-1).

Connection:
• Le: redundant feed to D797-1/K2:7
• Ri: redundant feed to D797-1/K2:8
Signal value:
1 Feed active.
0 No feed.
797-1 FRAME, POWER 2

page
–
Description: Battery voltage to frame control unit (D797-1).

Connection: 15-voltage from K315-1/87 via F54/4 and F58-2/1 to
D797-1/K2:11
Signal value:
1 Feed active.
0 No feed.

797-1 FRAME, 5V REF
page
–
Description: Reference voltage 5 v to sensors connected to frame con-

DIAG CAN/POWER 11(X) trol unit (D797-1) (voltage feed to pressure sensors).
797-1 FRAME
5V REF X.XXV Connection: digital out from 797-1/K1:8 to B768-1/1 and B768-2/1
005278
Function: 7.2.8 Hydraulic pressure sensor, lift cylinder and 7.7.8 Hy-
draulic pressure sensor, tilt cylinder
Signal value: X.XXV = 5.00 V. Important that signal value is stable (not
varying).


793 TRANSMISSION, POWER
page
–
Description: Battery voltage (30) to transmission control unit (D793).

Circuit diagram: Circuit 2.0-2A1
793 TRANSMISSION
POWER XX.XXV Connection: 30-voltage from F54/2 via F58-1/5 to D793/A1
IGNITION POWER XX.XXV
Function: 11.5.1.1 Battery voltage (30)
005279
SENSOR SUPPLY XX.XXV
793 TRANSMISSION, IGNITION POWER

page
–
Description: Ignition voltage (15) to transmission control unit (D793).

Connection: 15-voltage from K315/87 via F54/4 and F58-2/6 to D793/
S2
793 TRANSMISSION, SENSOR SUPPLY

page
–
Description: Voltage feed to sensors on transmission, reference volt-

age of 5 V.
Circuit diagram: Circuits 2.0-2A2, 2.0-2A3
Connection: 5V analogue Ref from D793/M1 to S221/1
Function: 2.8 Transmission control system
Signal value: XX.XXV = voltage on connection. The signal value
should be 8 V, stable (not vary).

797-2 FRAME (OPT), POWER
page
–

797-2 FRAME (OPT) Description: Ignition voltage (15) to frame option control unit (D797-2).
POWER XX.XXV Circuit diagram: Circuit 11.5-5
RED.POWER LE X RI X
005280
EME STOP POWER X Connection: 15-voltage from K315-1/87 via F54/4 and F58-2/3 to
D797-2/K2:1, D797-2/K2:9 and D797-2/K2:10

797-2 FRAME (OPT), RED. POWER

page
–
Description: Redundant voltage to frame option control unit (D797-2).

Circuit diagram: Circuit 11.6-2A
Connection:
• Le: redundant feed to D797-2/K2:7
• Ri: redundant feed to D797-2/K2:8
Signal value:
1 Feed active.
0 No feed.
797-2 FRAME (OPT), EME STOP POWER

page
–
Description: Emergency stop switch voltage to frame option control

unit (D797-2).
Connection: 15E-voltage from K3009-1/87 via K3009-2/87 and F58-3/
5 to D797-2/K2:11
Signal value:
1 Feed active.
0 No feed.

797-2 FRAME (OPT), 24V SENSOR SUPPLY
page
–
DIAG CAN/POWER 14(17)

797-2 FRAME (OPT) Description: Voltage feed 24 V to sensors connected to the frame op-
24V SENSOR SUPPLY XY tion control unit (D797-2).
5V REF X.XXV
005281
Connection: signal from digital out D797-2/K1:7 to S720-F/2 and

S720-R/2.
Function: 9.3.9 Sensor, reversible operator’s seat
Signal value:


797-2 FRAME (OPT), 5V REF

page
–
Not used.

791-1 ATTACHMENT, EME POWER
page
–
Description: Voltage feed to attachment control unit (D791-1).

791-1 ATTACHMENT(OPT)
EME POWER XX.XXV Connection: 15E voltage from K3009-1/87 via K3009-2/87, F58-3/1 to
RED.POWER LE X RI X D791-1/K2:1, K2:9, K2:10, K2:11
EME POWER 2 X 005282
Signal value:
XX.XXV = voltage on the connection. The signal value should be
22-30 V (battery voltage).
791-1 ATTACHMENT, RED. POWER

page
–
Description: Redundant voltage feed to attachment control unit (D791-

1).
Circuit diagram: Circuit 11.5-1, 11.5-6, 11.6-1, 11.6-2B, 11.6-2C
Connection:
Le: redundant voltage feed to D791/K2:7
Ri: redundant voltage feed to D791/K2:8
Signal value:
1 Feed active.
0 No feed.
791-1 FRAME, EME POWER 2

page
–
Description: Emergency stop switch voltage (15E) to attachment con-

trol unit (D791-1).
Connection: 15E voltage from K3009-1/87 via K3009-2/87, F58-3/1 to
D791-1/K2:11
Signal value:
1 Feed active.
0 No feed.


791-1 ATTACHMENT (OPT), 24V SENSOR SUPPLY
page
–
Description: Voltage feed to sensors connected to the attachment con-

DIAG CAN/POWER 16(X) trol unit (D791-1).
791-1 ATTACHMENT (OPT)
24V SENSOR SUPPLY XY Circuit diagram: Circuit 7.5-2, 7.9-2
5V REF X.XXV DCF360-450CSG
005283
Connection: digital out from 791-1/K1:10 to B769-1, B777-1, B7202L,
B7202R, B7203L, B7203R, B7204L, B7204R, B7205L and B7205R
Function: 7.5.8 Spreading position sensor, 7.9.1.6 Alignment position
sensor, 7.9.1.7 Twistlocks sensor
DCF 90-100 with twistlock attachment
Connection: digital out from 791-1/K1:10 to B769L, B769R, B777L,
B777R, B7203L, B7203R, B7204L, B7204R, B7205L and B7205R
Function: 7.5.6 Spreading position sensor, 7.9.1.7 Alignment position
sensor, 7.9.1.8 Twistlocks sensor
DCF 90-100 with lifting hook
Connection: digital out from 791-1/K1:10 to B769L, B769R, B777L,
B777R, B7203LU-2, B7203RU-2, B7203LL, B7203RL, B7203LU,
B7203RU, B7204L, B7204R, B7205LL and B7205RL
Function: 7.5.6 Spreading position sensor, 7.9.2.8 Alignment and de-
tection sensor, 7.9.2.9 Lock tongue sensor
Signal value:
01 No output signal, circuit OK or short-circuiting. Short-

circuiting can only be detected when the output signal is ac-
tive.

791-1 ATTACHMENT (OPT), 5V REF

page
–
Not used.


REDCAN STATUS CHECK
page
–
Description: Control function from the redundant CAN bus. The cab
DIAG CAN/POWER 17(X) control unit (D790-1) performs a segment check to determine whether
REDCAN STATUS CHECK all control units have contact and are connected in the right order. The
PRESS ENTER control system indicates the fault by numbering the cables between
the control units (segments) from 1 onwards. Segment 1 is always be-
005284
SEGMENT ERROR X
tween the cab control unit (D790-1) and the next control unit in se-
quence. The last segment is always between the KID control unit
(D795) and the cab control unit (D790-1). The segments in between
vary depending on machine configuration.
Circuit diagram: Circuit CAN bus group 11.6
D790-1 D791 D797-2 D797-1 Connection: -
CAN L CAN R CAN L CAN R CAN L CAN R CAN L CAN R
1 2 3 Function: 11.6.2 Redundant CAN-bus

5 4 Signal value:
CAN R CAN L
008878
D795
0 No errors.
DCF360-450CSG >0 X > 0, the number indicates incorrect segment. Use circuit di-
Segment numbering with maximum number of control agram to find the incorrect segment.
units. Control units marked with dashes are optional.
D790-1 D797-2 D797-1

CAN L CAN R CAN L CAN R CAN L CAN R
1 2
4 3
CAN R CAN L
008879
D795
DCF 280-500
Segment numbering with maximum number of control
units. Control units marked with dashes are optional.
8.4.2 LIGHTS
LIGHTS, description
page
–
This group covers lighting.

DIAGNOSIS
CAN/POWER LIGHTS CAB Confirm selection with function key for Enter.
CLIMATE HYD ENGINE
005285
OLS EXTRA

26 8 Control system – 8.4.2.1 LIGHTS, menu 1
8.4.2.1 LIGHTS, menu 1

MAIN LIGHT, SWITCH
page
–
Description: Signal from headlights switch.

DIAG LIGHTS 1(X)
MAIN LIGHT
SWITCH X Connection: signal from S100/1 to digital in D790-1/K6:5
Function: 9.6.1 Headlights.
005286
Signal value:
0 No signal.

PRESENT OUTPUT SIGNAL, SIDE LIGHTS
page
–
Description: Voltage feed to side running lights.

DIAG LIGHTS 2(X)
Circuit diagram: Circuit 9.6-5 and 9.6-6
PRESENT OUTPUT SIGNAL
Connection: digital out from D797-1/K1:2 to H416-1, H416-2, H417-1
SIDE LIGHTS XY and H417-2
005287
REAR LIGHTS XY
Function: 9.6.2 Running lights
Signal value:


PRESENT OUTPUT SIGNAL, REAR LIGHTS

page
–
Description: Voltage feed to rear lights.

Connection: digital out from D797-1/K1:33 to H412L and H412R
Function: 9.6.3 Rear lights
Signal value:



8 Control system – 8.4.2.3 LIGHTS, menu 3 27

HEADLIGHTS, SWITCH
page
–
Description: Lighting headlights front, switch.

DIAG LIGHTS 3(X)
HEAD LIGHTS
SWITCH X Connection: from S162:56A to digital in D790-2/K3:9
HEAD LE/RI XY
Function: 9.6.1 Headlights
005288
DIMMED LE/RI XY
Signal value:
0 No signal.
HEADLIGHTS, HEAD LE/RI

page
–
Description: Voltage feed to headlights, high beam.

Connection: digital out from D797-1/K1:15 to E402L-1 and E402R-1
Signal value:


HEADLIGHTS, DIMMED LE/RI

page
–
Description: Voltage feed to headlights, low beams.

Connection: digital out from D797-1/K1:28 to E400L and E400R
Signal value:




PRESENT INPUT SIGNAL, HAZARD SWITCH
page
–
Description: Signal from switch flashing hazard lights (Hazard).

DIAG LIGHTS 4(X)
PRESENT INPUT SIGNAL
HAZARD SWITCH X Connection: signal from S109/1 to digital in D790-1/K5:6
FLASH.SW. LE X RI X
Function: 9.7 Signalling system
005289
Signal value:
0 No signal.
PRESENT INPUT SIGNAL, FLASH.SW.

page
–
Description: Signal from switch direction indicators.

Connection:
• LE: signal from S161/6 to digital in D790-2/K8:8
• RI: signal from S161/1 to digital in D790-2/K8:9
Function: 9.6 Lighting system
Signal value:
0 No signal.

PRESENT OUTPUT SIGNAL HAZARD/FLASHER, LEFT F/R
page
–
Description: Voltage feed to direction indicator, left-hand side.

DIAG LIGHTS 5(X)
HAZARD/FLASHER Connection: digital out from D797-1/K1:30 to H422 and H426
LEFT F/R XY
Function: 9.6.6 Direction indicators, 9.6.7 Flashing hazard lights (Haz-
005290
RIGHT F/R XY
ard)
Signal value:



PRESENT OUTPUT SIGNAL HAZARD/FLASHER, RIGHT F/

page
–
R
Description: Voltage feed to direction indicator, right-hand side.
Connection: digital out from D797-1/K1:31 to H423 and H427
Function: 9.6.6 Direction indicators, 9.6.7 Flashing hazard lights (Haz-
ard)
Signal value:



ROTATING BEACON, SWITCH
page
–
Description: Signal from switch rotating beacon.

DIAG LIGHTS 6(X)
ROTATION BEACON
SWITCH X Connection: from S110/1 to digital in D790-1/K6:4
OUTPUT XY
Function: 9.6.8 Rotating beacon
005291
Signal value:
0 No signal.
ROTATING BEACON, OUTPUT

page
–
Description: Voltage feed to rotating beacon.

Connection: digital out from D790-1/K2:5 to H428
Function: 9.6.8 Rotating beacon
Signal value:

signal is active.
11 Output signal active, circuit OK.


PRESENT INPUT SIGNAL, BRAKE LIGHT SWITCH
page
–
Description: Signal from make-contact brake lights.

DIAG LIGHTS 7(X)
BRAKE LGT SWITCH X Connection: from S216/2 to digital in D797-1/K1:20
REVERSE LGT SIGNAL X
Function: 4.3.8 Make-contact brake lights
005292
Signal value:
0 No signal.
PRESENT INPUT SIGNAL, REVERSE LIGHT SIGNAL

page
–
Description: Signal from transmission control unit (D793) when re-

verse gear is activated.
Circuit diagram: Circuit Lighting group 9.6
Connection: -
Function: 9.6.5 Back-up light
Signal value:
1 Input signal active. Output signal "reverse gear active" from

transmission control unit (D793).
0 No signal.

PRESENT OUTPUT SIGNAL, BRAKE LGT
page
–
Description: Voltage feed to brake lights.

DIAG LIGHTS 8(X)
BRAKE LGT LE XY RI XY Connection:
REV. LGT LE XY RI XY
• LE: digital out from D797-1/K1:7 to H411L
005293
REVERSE ALARM XY
• RI: digital out from D797-1/K1:9 to H411R
Function: 9.6.4 Brake lights
Signal value:



PRESENT OUTPUT SIGNAL, REV LGT

page
–
Description: Voltage feed to reversing lights.

Connection:
• LE: digital out from D790-1/K2:6 to E405L
• RI: digital out from D790-1/K2:7 to E405R
Function: 9.6.5 Back-up light
Signal value:


PRESENT OUTPUT SIGNAL, BACK-UP (REVERSE)

page
–
ALARM
Description: Voltage feed to back-up alarm.
Connection: digital out from D797-1/K1:10 to H965
Function: 9.7.5 Back-up alarm
Signal value:



CAB LIGHT, MANUAL SWITCH
page
–
Description: Signal from switch lighting cab.

DIAG LIGHTS 9(X)
CAB LIGHT
MANUAL SWITCH X Connection: signal from D790-2/K8:11 to digital in D790-1/K11:2
DOOR SWITCH X
005294
OUTPUT XXX
Signal value:
0 No signal.

CAB LIGHT, DOOR SWITCH

page
–
Description: Signal from contact breaking door.

Connection: signal from S266-LE or S266-RI (connected in parallel) to
digital in D790-1/K11:3
Function: 9.10.2 Doors
Signal value:
0 No signal.
CAB LIGHT, OUTPUT

page
–
Description: Voltage feed to interior light cab.

Connection: digital out from D790-1/K11:6 to E434-1
Function: 9.6.11 Interior lighting
Signal value: XXX = 0-255 = 0-24 V (255 means 24 V which corre-
sponds to battery voltage).

WORKING LIGHT MAST, SWITCH
page
–
Description: Signal from switch for working light, mast.

DIAG LIGHTS 10(X)
WORKING LIGHT MAST
SWITCH X Connection: signal from S105-3/1 to digital in D790-1/K6:3
OUTPUT LE/RI XY
005295
Signal value:
0 No signal.
WORKING LIGHT MAST, OUTPUT

page
–
Description: Voltage feed to working light, mast.

Function: 9.6.9 Working light, mast
Signal value:

11 Output signal active, circuit OK or open circuit. Open circuit can

only be detected when the output signal is active.


WORKING LIGHT EXTRA OUTPUT, D797-1 C1 P42
page
–
Description: Voltage feed to auxiliary working light.

DIAG LIGHTS 11(X)
WORKING LIGHT EXTRA
OUTPUT Connection: digital out from D797-1/K1:42 to E404L-4 and E404R-4
D797-1 C1 P42 XY
Function: 9.1.4 Switch for working light, front wing, 9.1.5 Switch for
005296
D797-2 C1 P42 XY
working light, attachment, 9.1.6 Switch for working light, mast
Signal value:


WORKING LIGHT EXTRA OUTPUT, D797-2 C1 P42

page
–
Description: Voltage feed to auxiliary working light.

Function: 9.6.9 Working light, mast, 9.6.10 Working light, cab, 9.6.12
Working light, attachment, 9.6.14 Working light, front wing
Signal value:



WORK LIGHT CAB, SWITCH
page
–
Description: Signal from switch work light cab roof.

DIAG LIGHTS 12(X)
Circuit diagram: 9.6-1
WORKING LIGHT CAB
005297
OUTPUT 20' XY 40' XY

Signal value:
0 No signal.

WORK LIGHT CAB, OUTPUT

page
–
Description: Voltage feed to work light cab roof.

Connection:
• 20’: digital out from D790-1/K7:8 to E406L-2 and E406R-2
• 40’: digital out from D790-1/K10:8 to E406L-1 and E406R-1
Function: 9.6.10 Work light cab
Signal value:



WORKING LIGHT ATTACH, SWITCH
page
–
Description: Signal from switch work light attachment.

DIAG LIGHTS 13(X)
WORKING LIGHT ATTACH
OUTPUT LE XY RI XY
008895
Signal value:
0 No signal.
WORK LIGHT ATTACH, OUTPUT

page
–
Description: Voltage feed to working light, attachment.

Connection:
• LE: digital out from D791-1/K1:1 to E404L-3
• RI: digital out from D791-1/K1:15 to E404R-3
Function: 9.6.12 Work light attachment
Signal value:




SWITCH LIGHTS, OUTPUT
page
–
Description: Voltage feed to background lights in switches, panels and

DIAG LIGHTS 14(X) keys.
SWITCH LIGHTS Circuit diagram: Circuits 4.0-1, 5.2-1, 7.5-1, 7.9-1, 9.1-1, 9.3-1, 9.3-3,
9.4-1, 9.6-2, 9.6-3, 9.6-4, 9.6-1
OUTPUT XXX
005300
Connection:
output signal from D790-1/K6:1 to S117, S118, S139
output signal from D790-1/K6:2 to S105-2
output signal from D790-1/K6:4 to S110
output signal from D790-1/K8:15 to S169, S1010
Function: 9.6.11 Interior lighting
Signal value:
50 Means 4-5 V.
170 Means 15-16 V.

STEP LIGHT, SWITCH
page
–
Description: Signal from entry lighting switch.

DIAG LIGHTS 15(X)
STEP LIGHT
OUTPUT XXX
Function: 9.6.13 Entry lighting
008897
Signal value:
0 No signal.

36 8 Control system – 8.4.3 CAB
STEP LIGHT, OUTPUT

page
–
Description: Voltage feed to entry lighting.

Connection: digital out from D790-1/K11:6 to E433
Function: 9.6.13 Entry lighting
Signal value: XXX = 0-255 = 0-24 V (255 means 24 V which corre-
sponds to battery voltage).
8.4.3 CAB
CAB, description
page
–
This group covers functions in the cab.

DIAGNOSIS
CLIMATE HYD ENGINE
005301
OLS EXTRA
8.4.3.1 CAB, menu 1

WASHER, SWITCH
page
–
Description: Signal from gear and multi-function lever switch washer.

DIAG CAB 1(X) Circuit diagram: Circuit 9.5-1
WASHER
SWITCH X Connection: signal from S162/53C to digital in D790-2/K3:4
OUTPUT FRONT XY
Function: 9.5 Wiper/washer system
005541
OUTPUT REAR ROOF XY

Signal value:
0 No signal.
WASHER FRONT, OUTPUT

page
–
Description: Voltage feed to windscreen washer motor

Connection: digital out from D790-1/K10:13 to M651-1
Function: 9.5.4 Washer motor and reservoir
Signal value:

signal is active.

8 Control system – 8.4.3.2 CAB, menu 2 37
WASHER REAR ROOF, OUTPUT

page
–
Description: Grounding of motor washer roof and rear window. The

motor is supplied with voltage parallel with Motor windshield washing,
activation is controlled by controlling grounding of the motor. The mo-
tor is grounded at windshield washing if the wiper motor roof or rear
window is activated.
Connection: PWM out D790-1/K5:4 to M651-2
Function: 9.5.4 Washer motor and reservoir
Signal value:


8.4.3.2 CAB, menu 2

FRONT WIPER, SWITCH (1-3)
page
–
Description: Signal from multi-function lever switch wiper function.

DIAG CAB 2(X)
FRONT WIPER
SWITCH (1-3) X Connection:
OUTPUT XY
X = 1 Interval slow: signal from S162/J1 to digital in D790-2/K3:6
005542
FEEDBACK X
X = 2 Interval less slow: signal from S162/J2, digital in D790-2/
K3:7
X = 3 Interval continuous: signal from S162/53, digital in D790-2/
K3:8
Signal value:
1 Long interval.
2 Normal interval.
3 Continuous operation.

38 8 Control system – 8.4.3.3 CAB, menu 3
FRONT WIPER, OUTPUT

page
–
Description: Voltage feed to wiper front.

Connection: digital out from D790-1/K2:1 to M650-1/53
Function: 9.5.5 Wiper motor front
Signal value:

signal is active.
FRONT WIPER, FEEDBACK

page
–
Description: Signal from motor wiper front, indicates when wiper mo-
tion is completed.
Connection: signal from M650-1/31B to digital in D790-1/K4:13
Function: 9.5.5 Wiper motor front
Signal value:
1 Input signal active (wiper sweep).
0 No signal (resting position).
8.4.3.3 CAB, menu 3

REAR WIPER, SWITCH
page
–
Description: Status of rear window wiper switch on KIT control unit

DIAG CAB 3(X) (D790-2).
REAR WIPER
SWITCH X Circuit diagram: -
OUTPUT XY Connection: -
005543
FEEDBACK X
Signal value:
1 Input signal active. Key for continuous/interval pressed down.
0 No signal.

REAR WIPER, OUTPUT

page
–
Description: Voltage feed to direction windshield wiper rear.

Function: 9.5.7 Wiper motor rear
Signal value:

signal is active.
REAR WIPER, FEEDBACK

page
–
Description: Signal from motor windshield wiper rear, indicates when

wiper motion is completed.
Connection: signal from M650-2/31b to digital in D790-1/K12:2
Function: 9.5.7 Wiper motor rear
Signal value:
8.4.3.4 CAB, menu 4

ROOF WIPER, SWITCH
page
–
Description: Signal from switch wiper roof.

DIAG CAB 4(X)
Circuit diagram: -
ROOF WIPER
SWITCH X Connection: -
OUTPUT XY
005544
FEEDBACK X
Signal value:
1 Input signal active. Key for continuous/interval pressed down.
0 No signal.

ROOF WIPER, OUTPUT

page
–
Description: Voltage feed to wiper roof.

Connection: digital out from D790-1/K10:14 to wiper motor M650-3/53
Function: 9.5.6 Wiper motor roof
Signal value:


ROOF WIPER, FEEDBACK

page
–
Description: Signal from motor wiper roof, indicates when wiper mo-
tion is completed.
Connection: signal from M650-3/31B to digital in D790-1/K12:4
Function: 9.5.6 Wiper motor roof
Signal value:
8.4.3.5 CAB, menu 5

HORN, SWITCH
page
–
Description: Signal from switch horn.

DIAG CAB 5(X)
HORN
SWITCH X Connection: signal from S162/H to digital in D790-2/K3:2
SWITCH 2 X
Function: 9.7 Signal system
005545
OUTPUT XY
Signal value:
0 No signal.

HORN, SWITCH 2
page
–
Description: Signal from horn switch on hydraulic control panel.

Connection: signal from S149-3 to digital in D790-1/K9:10
Function: 9.7 Signal system
Signal value:
0 No signal.
HORN, OUTPUT
page
–
Description: Voltage feed to horn.

Circuit diagram: Circuits 9.7-1 and 9.7-3
Connection: digital out D790-1/K11:11 to H850 ( for compressor

horn, signal to relay K3016/86)
Function: 9.7.1 Horn
Signal value:

signal is active.
8.4.3.6 CAB, menu 6

BUZZER
page
–
Description: Voltage feed to buzzer for alarm indication panel, feed.

DIAG CAB 6(X)
BUZZER XY
SWITCH SEAT X Connection: digital out from D790-2/K8:4 to H853/1
ALARM X
Function: 9.3 Seat, 1 Engine, 8.2.1 Overload protection
005546
OP X
Signal value:



SWITCH SEAT
page
–
Description: Signal from sensor operator in seat.

Connection: signal from S230/1 to D790-1/K11:14
Function: 9.3.14 Sensor operator in seat
1 Input signal active. Operator in seat.
0 No signal. No operator in seat.
ALARM
page
–
Description: Status for alarm indication panel, warning from control

system.
Circuit diagram: -
Connection: -
Function: 8.1.2 Information display
1 Conditions for activation of buzzer from seat switch and park-

ing brake are fulfilled.
0 Conditions for activation of buzzer are not fulfilled.
OP
page
–
Description: Status for overload protection warning from control sys-

tem.
Circuit diagram: Circuit 8.2_2
Connection: -
Function: 8.2.1 Overload protection
Signal value:
1 Conditions for activation of buzzer fulfilled, that is, overload

system is indicating.
0 Conditions for activation of buzzer are not fulfilled.
8.4.3.7 CAB, menu 7

FUEL, SENSOR VALUE
page
–
Description: Signal from sensor fuel level.

DIAG CAB 7(X)
FUEL
SENSOR VALUE XXXohm Connection: analogue rheostat signal from B757 to D797-1/K2:15
PROC XXX
Function: 1.2.2 Sensor fuel level
009182
Signal value: XXXOHM = Current resistance value from sensor fuel

level in ohm.

FUEL, PROC
page
–
Description: Control system’s interpretation of signal from fuel tank

sensor.
Circuit diagram: -
Connection: -
Function: 1.2.2 Sensor fuel level
Signal value: XXX = 0-100 = 0-100 % = Fuel volume in tank.
8.4.3.8 CAB, menu 8

SEAT HEATER, SWITCH
page
–
Description: Signal from seat heater switch.

DIAG CAB 8(X)
SEAT HEATER
OUTPUT XY
Function: 9.3 Seat
005548
Signal value:
0 No signal.
SEAT HEATER, OUTPUT

page
–
Description: Voltage feed to seat heating relay.

Connection: digital out from D790-1/K10:7 to K383/86
Function: 9.3.3 Heating coil
Signal value:



44 8 Control system – 8.4.4 CLIMATE
8.4.4 CLIMATE
CLIMATE, description
page
–
This group covers the cab’s climate control system.

DIAGNOSIS
CLIMATE HYD ENGINE
005302
OLS EXTRA
8.4.4.1 CLIMATE, menu 1

PRESENT INPUT SIGNAL, REQUIRED TEMP
page
–
Description: Set value for desired temperature.

DIAG CLIMATE 1(X)
REQUIRED TEMP XXX Connection: signal from S117/3 to analogue in D790-1/K5:8
PRESENT TEMP XXX
Function: 9.4 Heating, ventilation and air conditioning
005549
WATER VALVE FEEDB. XXX

Signal value: XXX = 160-280 = 16-28 °C Preset temperature shown in
tenths of degrees and adjusted in increments of half degrees (200 =
20 °C). Test by increasing or decreasing temperature with the temper-
ature switch on the panel.
PRESENT INPUT SIGNAL, PRESENT TEMP

page
–
Description: Signal from sensor cab temperature.

Connection: signal from B775-1/2 to input D790-1/K4:8
Function: 9.4.17 Sensor cab temperature
Signal value: XXX = Cab’s interior temperature in tenths of degrees
(200 = 20 °C).
PRESENT INPUT SIGNAL, WATER VALVE FEEDB.

page
–
Description: Water valve’s position (opening in percent).

Connection: signal from Y673/9 to analogue in D790-1/K10:4
Function: 9.4.5 Water valve
Signal value: XXX = 0-100 = 0-100% = Water valve’s opening in %. 0
= Closed. 100 = Fully open.

TEMP COIL
page
–
Description: Temperature of the air out from the fan. The sensor is lo-
DIAG CLIMATE 2(X) cated in the air distributor.
TEMP COIL XXX
TEMP COOLANT XXX Circuit diagram: Circuit 9.4-1
TEMP AMBIENT XXX Connection: signal from B775-2 to input D790-1/K4:10
005550
TEMP DE-ICE XXX

Function: 9.4.16 Sensor temperature outlet fan
Signal value: XXX = Temperature of the air blown into the cab in tenths
of degrees (200 = 20 °C).

8 Control system – 8.4.4.3 CLIMATE, menu 3 45
TEMP COOLANT
page
–
Description: Coolant temperature (temperature of the engine’s cool-

ant). Signal is retrieved from the engine via CAN bus drivetrain.
Circuit diagram: Circuits 9.4-1, 9.4-2
Connection: from engine via CAN bus, see PRESENT INPUT SIG-
NAL, COOLANT TEMP page 62.
Function: 1.7.9 Sensor coolant temperature
Signal value: XXX = Engine temperature in tenths of degrees (200 =
20 °C).
TEMP AMBIENT
page
–
Description: Outdoor temperature. Heat radiation from engine and sun

may affect the value since the sensor is located on the rear of the cab
roof.
Connection: signal from B774/2 to input D790-1/K4:9
Function: 9.4.18 Sensor ambient temperature
Signal value: XXX = Outdoor temperature in tenths of degrees (200 =
20 °C).
TEMP DE-ICE
page
–
Description: Temperature in refrigerant circuit.

Connection: signal from B775-3/2 to input D790-1/K4:11
Function: 9.4.12 Sensor temperature refrigerant
Signal value: XXX = Refrigerant temperature in tenths of degrees (200
= 20 °C).

PRESENT INPUT SIGNAL, PRESSURE SWITCH
page
–
Description: Signal from refrigerant pressure switch.

DIAG CLIMATE 3(X)
PRESSURE SWITCH X Connection: signal from S246/2 to digital in D797-1/K1:40
Function: 9.4.10 Pressure switch
005551
Signal value:
1 Input signal active. Press Ok.
0 No signal, too high or too low pressure.

46 8 Control system – 8.4.4.4 CLIMATE, menu 4

PRESENT INPUT SIGNAL, WATER VALVE
page
–
Description: Signal from water valve, the voltage is a measure of the

DIAG CLIMATE 4(X) position.
WATER VALVE XX.XXV Circuit diagram: Circuit 9.4-2
DRAUGHT VALVE XX.XXV Connection: signal from Y673/9 to analogue in D790-1/K10:4
005552
Signal value: XX.XXV = 0.50 - 4.50 V
PRESENT INPUT SIGNAL, DRAUGHT VALVE

page
–
Description: Signal from the engine to the air distributor. Voltage is a

measure of the valve’s position.
Connection: signal from Y672/9 to analogue in D790-1/K4:7
Function: 9.4.14 Air distributor
Signal value: XX.XXV = 0.50 - 4.50 V

PRESENT INPUT SIGNAL, REQUIRED TEMP
page
–
Description: Signal from switch temperature. Voltage when switch is

DIAG CLIMATE 5(X) pressed in voltage level indicates increase or decrease of the temper-
PRESENT INPUT SIGNAL ature.
REQUIRED TEMP XX.XXV
REQ. DRAUGHT XX.XXV Circuit diagram: Circuit 9.4-1
005553
REQ. FAN SPEED XX.XXV Connection: signal from S117/3 to analogue in D790-1/K5:8
Signal value: XX.XXV ∼ 2.4 / 0 / 5.0 V = Increase / - / decrease.
PRESENT INPUT SIGNAL, REQ. DRAUGHT

page
–
Description: Signal from switch air distribution, voltage when switch is

pressed in. The voltage level indicates change of air control against
windshield (up) or floor (down). The valve’s position changes in steps
between windshield - floor.
Connection: signal from S139/3 to analogue in D790-1/K5:9
Signal value: XX.XXV ∼ 2.4 / 0 / 5.0 V = Up / - / down.
PRESENT INPUT SIGNAL, FAN SPEED

page
–
Description: Signal from switch fan speed, switch controls increase or

decrease of fan speed. Speed is endless adjustable. The voltage level
indicates if the speed should be increased or decreased.
Connection: signal from S118/3 to analogue in D790-1/K5:7
Function: 9.4 Heating, ventilation and climate control unit
Signal value: XX.XXV ∼ 2.4 / 0 / 5.0 V = Increase / - / decrease.


PRESENT OUTPUT SIGNAL, FAN SPEED
page
–
Description: Current control of fan motor, speed is controlled with

DIAG CLIMATE 6(X) PWM-control of grounding (of fan motor).
FAN SPEED XXX Circuit diagram: Circuit 9.4-2
RECIRKULATION XY Connection: analogue out from D790-1/K2:2 to M657/31
005554
COMPRESSOR XY
Function: 9.4.3 cab fan
Signal value: XXX = 0-255 = Fan speed (255 = max. fan speed).
PRESENT OUTPUT SIGNAL, RECIRCULATION

page
–
Description: Voltage feed to motor for fresh air and recirculation damp-
er.
Connection: digital out from D790-1/K2:3 to M612
Function: 9.4.2 Fresh air and recirculation damper
Signal value:

signal is active.
PRESENT OUTPUT SIGNAL, COMPRESSOR

page
–
Description: Voltage feed of AC compressor’s electromagnetic clutch.

Controls cut-in and cut-out of the compressor. Two outputs are con-
nected in parallel to handle the current.
Connection: digital out from D797-1/K1:25 and D797-1/K1:29 to M645
Function: 9.4.7 Compressor
Signal value:



48 8 Control system – 8.4.4.7 CLIMATE, menu 7

OUTPUT WATER VALVE, CLOCKWISE
page
–
Description: Voltage feed to water valve, for opening. The valve is con-
DIAG CLIMATE 7(X) nected to an H-bridge. The signal can only be diagnosed when the
OUTPUT WATER VALVE valve’s position changes. The valve’s opening and closing is control-
CLOCKWISE XY XY led by the climate control unit’s software depending on desired tem-
ANTI-CLOCKWISE XY XY perature, outside temp. cab temperature and coolant temperature,
thereafter it may be difficult to determine if the valve is working as it
should.
24V
Connection: digital out from D790-1/K4:1 via R3 to Y673/5 and from
D790-1/K4:2 via R4 to Y673/6
M Signal value: motor runs clockwise row 1: 11 11 row 2: 00 11

005555
0V can only be detected when the output signal is active.

H-bridge

OUTPUT WATER VALVE, COUNTER-CLOCKWISE

page
–
Description: Voltage feed to water valve, for closing. The valve is con-
nected to an H-bridge. The signal can only be diagnosed when the
valve’s position changes. The valve’s opening and closing is control-
led by the climate control unit’s software depending on desired tem-
perature, outside temp. cab temperature and coolant temperature,
thereafter it may be difficult to determine if the valve is working as it
should.
D790-1/K4:2 via R4 to Y673/6
Signal value: motor runs counter-clockwise row 1: 00 11, row 2: 11 11




OUTPUT DRAUGHT VALVE, CLOCKWISE
page
–
Description: Voltage feed to motor for the air distributor, rotation clock-
DIAG CLIMATE 8(X) wise. Is connected to an H-bridge. Signal can only be diagnosed when
OUTPUT DRAUGHT VALVE the air distributor’s position changes.
CLOCKWISE XY XY
ANTI-CLOCKWISE XY XY Circuit diagram: Circuit 9.4-2
D790-1/K4:4 via R6 to Y672/6
24V
Signal value: motor runs clockwise row 1: 11 11, row 2: 00 11
M 01 No output signal, circuit OK or short-circuiting. Short-circuiting


005556
0V can only be detected when the output signal is active.

H-bridge
OUTPUT DRAUGHT VALVE, COUNTER-CLOCKWISE

page
–
Description: Voltage feed to motor for the air distributor, rotation coun-
ter-clockwise. Motor is connected to an H-bridge. Signal can only be
diagnosed when the air distributor’s position changes.
D790-1/K4:4 via R6 to Y672/6
Signal value: motor runs counter-clockwise row 1: 00 11, row 2: 11 11



50 8 Control system – 8.4.5 HYD
8.4.5 HYD
HYD, description
page
–
This group covers the hydraulic functions.

DIAGNOSIS
CLIMATE HYD ENGINE
005303
OLS EXTRA
8.4.5.1 HYD, menu 1

HYDRAULIC OIL, TEMP
page
–
Description: Signal from sensor hydraulic oil temperature.

DIAG HYDRAULIC 1(X)
HYDRAULIC OIL
TEMP XXX Connection: signal from B776/1 to temperature in D797-1/K2:13
FAN XY
Function: 10.6.4 Sensor hydraulic oil temperature
010070
SET OUTPUT + - X
Signal value: XXX = Temperature in tenths of degrees (200 = 20 °C).
HYDRAULIC OIL, FAN

page
–
Description: Voltage feed cooling fan hydraulic oil.

Connection: digital out from D797-1/K1:14 to M668/1
Function: 10.6.3 Cooling fan
Signal value:
HYDRAULIC OIL, SET OUTPUT +/-

page
–
Description: Functionality test of hydraulic oil cooling fan.

Connection: digital out from D797-1/K1:14 to M668/1 is activated or
deactivated with +/-
Signal value:

signal is active.

8 Control system – 8.4.5.2 HYD, menu 2 51
8.4.5.2 HYD, menu 2

BRAKE COOLANT OIL, TEMP
page
–
DIAG HYDRAULIC 2(X)

BRAKE COOLANT OIL
TEMP XXX
FAN XY FEEDBACK X
010071
SET OUTPUT + - X
Menu for DCF360-450CSG

Description: Signal from sensor brake oil temperature.
DIAG HYDRAULIC 2(X)
BRAKE COOLANT OIL
TEMP XXX Connection: signal from B772/1 to temperature in D797-1/K2:6
FAN XY
Function: DCF360-450CSG 4.8.10 Brake oil temperature sensor, DCF
010072
SET OUTPUT + - X
90-100 4.8.10 Hydraulic oil temperature sensor
Menu for DCF 280-500 Signal value: XXX = Temperature in tenths of degrees (200 = 20 °C).
BRAKE COOLANT OIL, FAN

page
–
Description: Voltage feed to cooling fan brake oil.

Connection: digital out from D797-1/K1:3 via K3774/86 to M674/1
Signal value:
BRAKE COOLANT OIL, FEEDBACK

page
–
Description: Signal from the brake oil cooling fan.

Connection: signal from M674/1 to D797-1/K1:3 via K3774/86
Signal value:

52 8 Control system – 8.4.5.3 HYD, menu 3
BRAKE COOLANT OIL, SET OUTPUT +/-

page
–
Description: Voltage feed to cooling fan brake oil.

Connection: digital out from D797-1/K1:3 via K3774/86 to M674/1 is
activated or deactivated with +/-
Signal value:


8.4.5.3 HYD, menu 3

HYDRAULIC PRESSURE, LIFT CYLINDER
page
–
Description: Pressure on lift cylinders’ piston side (C+). For voltage

DIAG HYDRAULIC 3(X) value, see PRESENT INPUT SIGNAL, LIFT CYLINDER page 134.
HYDRAULIC PRESSURE
LIFT CYLINDER XXX Connection: signal from B768-1/3 to analogue in D797-1/K1:21
TILT CYLINDER XXX
Function: 7.2.8 Sensor hydraulic pressure lift cylinder
Signal value: XXX = 0-250 = Hydraulic pressure 0 - 25 MPa. (255 =
C- incorrect signal.)
C+
007239
HYDRAULIC PRESSURE, TILT CYLINDER

page
–
Description: Pressure on the tilt cylinders’ rod side (C-). For voltage
value, see PRESENT INPUT SIGNAL, TILT CYLINDER page 134.
Connection: signal from B768-2/3, analogue in D797-1/K1:22
Function: 7.7.8 Hydraulic pressure sensor, tilt cylinder
Signal value: XXX = 0-250 = Hydraulic pressure 0 - 25 MPa. (255 =
incorrect signal.)

8.4.5.4 HYD, menu 4

PRESSURE SWITCHES, BRAKE PRESSURE
page
–
Description: Signal from normally closed (NC) switch, brake pressure.

DIAG HYDRAULIC 4(X)
PRESSURE SWITCHES
BRAKE PRESSURE X Connection: signal from S204/2 to analogue in D797-1/K1:13
BRAKE LIGHT PRESS. X
Function: 4.3.7 Normally open (NO) switch, brake pressure
007240
DECLUTCH PRESSURE X
Signal value:
0 No signal.
PRESSURE SWITCHES, BRAKE LIGHT PRESSURE

page
–
Description: Signal from make-contact brake lights.

Connection: signal from S216/2 to digital in D797-1/K1:20
Function: 4.3.8 Make-contact brake lights
Signal value:
0 No signal.
PRESSURE SWITCHES, DECLUTCH PRESSURE

page
–
Description: Signal from normally closed (NC) switch, disengagement.

Connection: signal from S220-2/2 to analogue in D797-1/K1:27
Function: 2.8.2 Normally closed (NC) switch, disengagement
Signal value:
0 No signal.

8.4.5.5 HYD, menu 5

P-BRAKE, SWITCH
page
–
Description: Signals from switch parking brake. Two signals, one for
DIAG HYDRAULIC 5(X) released parking brake and one for applied parking brake. Both sig-
P-BRAKE nals must be valid to enable release of parking brake.
SWITCH X/Y
FEEDBACK SWITCH X Circuit diagram: Circuit 4.0-1
007241
VALVE XY Connection: signal from S107/1 to digital in D790-1/K8:13 and from
S107/7 to digital in D790-1/K8:5
Function: 4.5 Parking brake system
Signal value:
1/0 Open, parking brake released.
0/1 On, parking brake applied.
P-BRAKE, FEEDBACK SWITCH

page
–
Description: Signal from break-contact parking brake.

Connection: signal from S200 to analogue in D797-1/K1:41
Function: 4.5.5 Normally open (NO) switch, parking brake
Signal value:
0 No signal.
P-BRAKE, VALVE
page
–
Description: Voltage feed to Solenoid valve parking brake.

Connection: digital out from D797-1/K1:34 to solenoid valve Y642/1
Function: 4.5.3 Solenoid valve parking brake
Signal value:



8.4.5.6 HYD, menu 6

CUT OFF HYDRAULIC PUMPS, PUMP 2
page
–
Description: Voltage feed to solenoid valve for disconnection of the hy-

DIAG HYDRAULIC 6(X) draulic pump
CUT OFF HYDRAULIC
PUMPS Circuit diagram: Circuit 10.4-1
PUMP 2 XY Connection: digital out from D797-1/K1:39 to solenoid valve Y6062
007242
PUMP ATTACHMENT XY
Function: 10.4.3 Vane pump with fixed displacement
Signal value:


CUT OFF HYDRAULIC PUMPS, PUMP ATTACHMENT

page
–
Description: Voltage feed to solenoid valve for disconnection of the hy-

draulic pump for the attachment.
Connection: digital out from D797-1/K1:35 to solenoid valve Y6062-2
Function: 10.4.2 Axial piston pump with variable displacement
Signal value:


8.4.5.7 HYD, menu 7

PRESENT OUTPUT SIGNAL EXTRA HYD PUMP, VALVE
page
–
Only applies to DCF 90-100

DIAG HYDRAULIC 7(X)
Description: Voltage feed to solenoid valve for quick-lift pump.
EXTRA HYD PUMP Circuit diagram: 10.4-1
VALVE XY
Connection: digital out from D797-1/K1:39 to solenoid valve Y6062
010073
SET OUTPUT + - X
Signal value:
1 Output signal active.
0 No output signal.

PRESENT OUTPUT SIGNAL EXTRA HYD PUMP, SET

page
–
OUTPUT +/-
Description: Activate or deactivate the quick-lift pump.
Connection: digital out from D797-1/K1:39 to solenoid valve Y6062 is
activated or deactivated with +/-
Signal value:
0 No output signal.
8.4.5.8 HYD, menu 8

PRESENT OUTPUT SIGNAL, PRESSURE TO ATTACHM.
page
–
VALVE
Only applies to DCF 90-100
DIAG HYDRAULIC 8(X)
Description: Voltage feed to solenoid valve for main pump relief (pres-
PRESSURE TO ATTACHM. surised attachment).
VALVE XY Circuit diagram: 10.4-1
010074
SET OUTPUT + - X
Signal value:
0 No output signal.
PRESENT OUTPUT SIGNAL, PRESSURE TO ATTACHM,

page
–
SET OUTPUT +/-

Description: Begin sending or cut off hydraulic pressure to the attach-
ment.
is activated or deactivated with +/-
Signal value:
0 No output signal.

8 Control system – 8.4.6 ENGINE 57
8.4.6 ENGINE
ENGINE, description
page
–
This group covers engine functions.

DIAGNOSIS
CLIMATE HYD ENGINE
005306
OLS EXTRA
8.4.6.1 ENGINE, menu 1

PRESENT INPUT SIGNAL, ACCELERATOR
page
–
Description: Signal from accelerator pedal.

DIAG ENGINE 1(X)
ACCELERATOR X.XXV Connection: signal from B690-1/2 to analogue in D790-1/K6:11
REQUIRED SPD PROC XXX
Function: 1 Engine
008898
REQUIRED SPD RPM XXXX

Signal value: X.XXV = 0.50 - 4.50 V
PRESENT INPUT SIGNAL, REQUIRED SPD PROC

page
–
Description: Required engine speed (in percent) which is sent from the
cab control unit (D790-1) to the engine control unit (D794) via the CAN
bus drivetrain.
Circuit diagram: -
Connection: -
Function: 1.9 Control system, engine
Signal value: XXXX = 0 - 100%
PRESENT INPUT SIGNAL, REQUIRED SPD RPM

page
–
Description: Required engine speed in rpm which is sent from the cab
control unit (D790-1) to the engine control unit (D794) via the CAN bus
drivetrain.
Circuit diagram: -
Connection: -
Signal value: XXXX = 0-2010 rpm

RESENT INPUT SIGNAL, ENGINE SPEED EDC
page
–
Description: Engine speed from engine control unit (D794) to the cab
DIAG ENGINE 2(X) control unit (D790-1) via the CAN bus drivetrain. The actual value for
PRESENT INPUT SIGNAL engine speed.
ENGINE SPEED EDC XXXX
ENGINE SPEED TCU XXXX Circuit diagram: -
005308
Connection: -
Function: 1.9.2 Sensor engine rpm
Signal value: XXXX = active speed in rpm.

58 8 Control system – 8.4.6.3 ENGINE, menu 3
PRESENT INPUT SIGNAL, ENGINE SPEED TCU

page
–
Description: Engine speed from transmission control unit (D793) to the

cab control unit (D790-1) via the CAN bus drivetrain. The actual value
for engine speed.
Circuit diagram: -
Connection: -
Function: 2.2.5 Sensor engine rpm and oil temperature transmission
Signal value: XXXX = active speed in rpm.

PRESENT INPUT SIGNAL, PRESENT TORQUE
page
–
Description: Actual torque from engine control unit (D794). Percent-

DIAG ENGINE 3(X) age torque use of engine’s capacity.
PRESENT TORQUE XXX Circuit diagram: -
REQUIRED TORQUE XXX Connection: -
005309
PRES TORQUE @ RPM XXX

Signal value: XXXX = 0 - 100%
PRESENT INPUT SIGNAL, REQUIRED TORQUE

page
–
Description: Requested torque from cab control unit (D790-1) to en-

gine control unit (D794).
Circuit diagram: -
Connection: -
Signal value: XXXX = 0-100%
PRESENT INPUT SIGNAL, PRES TORQUE @ RPM

page
–
Description: Available torque at current engine speed.

Circuit diagram: -
Connection: -
Signal value: XXX = 0-100%

8 Control system – 8.4.6.4 ENGINE, menu 4 59

PRESENT INPUT SIGNAL, PREHEAT SWITCH
page
–
DIAG ENGINE 4(X)

PRESENT INPUT SIGNAL Description: Signal from ignition, preheating position. Only used on
PREHEAT SWITCH X machines with Volvo engines.
CRANK ENGINE SWITCH X
005310
D+ X
Function: 1 Engine, 1.10.1 Preheating
Signal value:
0 No signal.
PRESENT INPUT SIGNAL, CRANK ENGINE SWITCH

page
–
Description: Signal from ignition, start position.

Function: 1.1.1 Ignition switch, 1.11 Start and stop
Signal value:
0 No signal.
PRESENT INPUT SIGNAL, D+

page
–
Description: Signal from alternator, indicates if alternator supplies cur-

rent.
Circuit diagram: Circuits 11.5-1, 1.0-2A, 1.0-1
Connection: signal from G660/D+ to digital in D797-1/K2:16
Function: 11.4.1 Alternator
Signal value:
0 No signal.


PRESENT OUTPUT SIGNAL, PREHEAT
page
–
Description: Status for preheating of induction air.

DIAG ENGINE 5(X)
Circuit diagram: -
PREHEAT X Connection:
CRANK ENGINE CAN X
Volvo: software signals on CAN-bus drivetrain
007639
CRANK ENGINE WIRE XY
Cummins: controlled by engine’s control system.
Function: 1.10.1 Preheating
Signal value:
0 No output signal.
PRESENT OUTPUT SIGNAL, CRANK ENGINE CAN

page
–
Description: Voltage feed, starter motor. For Volvo TAD760VE,

TAD950VE, TAD952VE and TAD1250VE.
Circuit diagram: -
Connection: software signals on CAN-bus drivetrain.
Function: 1.11 Start and stop
Signal value:
0 No output signal.
PRESENT OUTPUT SIGNAL, CRANK ENGINE WIRE

page
–
Description: Voltage feed to starter motor relay. For Cummins QSM11.

Circuit diagram: 1.0-1, 1.0-2B1
Connection: digital out D797-1/K1:32 to K360/86.
Function: 1.11 Start and stop
Signal value:

tive.



PRESENT INPUT SIGNAL, OIL PRESSURE
page
–
Description: Engine oil pressure. CAN bus message from engine con-
DIAG ENGINE 6(X) trol unit (D794) to cab control unit (D790-1).
OIL PRESSURE XX.X Circuit diagram: see supplier documentation, engine
BOOST PRESSURE XX.X Connection:
008899
OIL LEVEL XXX
Volvo TAD760VE: signal from "2 oil pressure sensor" to engine
control unit (D794) "Connector B" sleeve 11
Volvo TAD950VE, TAD952VE, TAD1250VE: signal from "28 oil
temperature and oil pressure sensor" to engine control unit (D794)
"Connector B" sleeve 11
Cummins QSM11: signal from "oil pressure/temperature sensor"
to engine control unit (D794) "Sensor connector" sleeve 44
Function: 1.8.3 Sensor oil pressure engine
Signal value= XX.X = pressure in bar.
PRESENT INPUT SIGNAL, BOOST PRESSURE

page
–
Description: Charge air pressure. CAN bus message from engine con-
trol unit (D794) to cab control unit (D790-1).
Circuit diagram: See supplier documentation, engine
Connection:
Volvo TAD760VE: signal from "33 charge air pressure sensor" to
engine control unit (D794) "Connector A" sleeve 22
Volvo TAD950VE, TAD952VE, TAD1250VE: signal from "23
charge air pressure/temperature sensor" to engine control unit
(D794) "Connector A" sleeve 22
Cummins QSM11: signal from "Intake manifold (boost) pressure
sensor" to engine control unit (D794) "Sensor connector" sleeve
39
Function: 1.6.5 Sensor boost pressure
Signal value= XX.X = pressure in bar.
PRESENT INPUT SIGNAL, OIL LEVEL

page
–
Only Volvo TAD950VE, TAD952VE and TAD1250VE engines

Description: Engine oil level. CAN bus message from engine control
unit (D794) to cab control unit (D790-1).
Circuit diagram: See supplier documentation, engine
Connection: Volvo TAD950VE, TAD952VE, TAD1250VE: signal from
"15 Oil level sensor" to engine control (D794) "connector A" sleeve 3
Function: -
Signal value: XXX = 0-100 = 0-100% = Oil level in percent.


PRESENT INPUT SIGNAL, OIL TEMP
page
–
Description: Engine oil temperature. CAN bus message from engine

DIAG ENGINE 7(X) control unit (D794) to cab control unit (D790-1).
OIL TEMP XXX Circuit diagram: see supplier documentation, engine
COOLANT TEMP XXX Connection:
005313
INTAKE MAIN.TEMP XXX
Volvo TAD760VE: signal from "1 oil temperature/level sensor" to
engine control unit (D794) "connector A" sleeve 31
Volvo TAD950VE, TAD952VE, TAD1250VE: signal from "28 oil
temperature/pressure sensor" to engine control unit (D794) "Con-
nector A" sleeve 31
Cummins QSM11: signal from "oil pressure/temperature sensor"
sleeve 4 to engine control unit (D794) "Sensor connector" sleeve
42
Function: 1.8.7 Sensor oil temperature
Signal value: XXX = 200 equals 20 °C.
PRESENT INPUT SIGNAL, COOLANT TEMP

page
–
Description: Coolant temperature. CAN bus message from engine

control unit (D794) to cab control unit (D790-1).
Circuit diagram: see supplier documentation, engine
Connection:
Volvo TAD760VE: signal from "4 coolant temperature sensor" to
engine control unit (D794) "Connector B" sleeve 27
Coolant temperature sensor" to engine control (D794) "connector
B" sleeve 27
Cummins QSM11: signal from "Coolant temperature sensor" to
engine control unit (D794) "Sensor connector" sleeve 02
Function: 1.7.9 Sensor coolant temperature
PRESENT INPUT SIGNAL, INTAKE MAIN.TEMP

page
–
Description: Charge air temperature. CAN bus message from engine

control unit (D794) to cab control unit (D790-1).
Circuit diagram: see supplier documentation, engine
Connection:
Volvo TAD760VE: signal from "34 charge air pressure/tempera-
ture sensor" to engine control unit (D794) "connector A" sleeve 47
Charge air pressure/temperature sensor" to engine control unit
(D794) "Connector B" sleeve 47
Cummins QSM11: signal from "Intake manifold (boost) tempera-
ture sensor" to engine control unit (D794) "Sensor connector"
sleeve 38
Function: 1.6.6 Sensor charge-air temperature


PRESENT EDC ERROR, NO. OF ACT ERROR
page
–
Description: Number of error codes from engine control unit EDC

DIAG ENGINE 8(X) (D794).
PRESENT EDC ERROR
NR OF ACT ERROR XX Circuit diagram: -
SPN XXXX Connection: -
005314
FMI XX
Function: 1.9 Control system
Signal value: XX = number of active error codes.
PRESENT EDC ERROR, SPN

page
–
Description: SPN number for the first error code from engine control
unit (D794). SPN indicates the malfunction area, i.e. what component
or signal is defective. Error codes are shown with SPN/FMI in error
code menus.
Circuit diagram: -
Connection: -
Function: 8.3 Error codes
Signal value: XXXX = error code number. Use the error code list; see
section D Error codes.
PRESENT EDC ERROR, FMI

page
–
Description: FMI number for the first error code from the engine control
unit (D794). FMI indicates error type, e.g. short circuit or low value. Er-
ror codes are shown with SPN/FMI in error code menus.
Circuit diagram: -
Connection: -
Function: 8.3 Error codes
Signal value: XX = fault type number. Use the error code list; see sec-
tion D Error codes.

FUEL CONSUMPTION, MOMENTARY l/h
page
–
Description: Current fuel consumption in litres/hour.

DIAG ENGINE 9(X)
Circuit diagram: -
FUEL CONSUMPTION
MOMENTARY l/h XXX Connection: -
Function: 1.2 Fuel system
005315
Signal value: XXX = fuel consumption in l/h

64 8 Control system – 8.4.7 TRANSM
8.4.7 TRANSM
TRANSM, description
page
–
This group covers transmission functions.

DIAGNOSIS
CLIMATE HYD ENGINE
005324
OLS EXTRA
8.4.7.1 TRANSM, menu 1

PRESENT INPUT SIGNAL, BRAKE PEDAL
page
–
Description: Not used.
PRESENT INPUT SIGNAL, DECLUTCH SWITCH

page
–
Description: Signal from declutch pedal.

DIAG TRANSM. 1(X)
BRAKE PEDAL X.XXV Connection: signal from S220-1/2 to digital in D790-1/K6:14
DECLUTCH SWITCH X
Function: 2 Transmission
005325
DECLUTCH PRESS SW. X

Signal value:
1 Input signal active. Declutch pedal pressed down.
0 No signal.
PRESENT INPUT SIGNAL, DECLUTCH PRESS SW.

page
–
Description: Signal from normally closed (NC) switch, disengagement

(pressure switch).
Connection: signal from S220-2/2 to digital in D797-1/K1:27
Function: 2.8.2 Normally closed (NC) switch, disengagement
Signal value:
0 No signal.

SWITCHES, FORWARD
page
–
Description: Signal from gear and multi-function lever (forward).

DIAG TRANSM. 2(X)
SWITCHES
FORWARD X Connection: signal from S162/F to digital in D790-2/K3:11
REVERSE X
005326
SHIFT MODE X
Signal value:
1 Input signal active. Travel direction forward selected.
0 No signal.

8 Control system – 8.4.7.3 TRANSM, menu 3 65
SWITCHES, REVERSE
page
–
Description: Signal from gear and multi-function lever (reverse).

Connection: signal from S162/R to digital in D790-2/K3:12
Signal value:
1 Input signal active. Travel direction reverse selected.
0 No signal.
SWITCHES, SHIFT MODE

page
–
Description: Signal from shifting program switch. Status on CAN bus

from KIT control unit (D790-2). The switches are integrated in the KIT
Circuit diagram: -
Connection: -
Signal value:
1 Shifting program 1 selected.
2 Shifting program 2 selected.
4 Automatic shifting selected.

PRESENT VALUE, FORWARD
page
–
Description: Status for forward direction of travel from transmission

DIAG TRANSM. 3(X) control unit (D793). Indicates if forward drive is activated in the trans-
PRESENT VALUE mission.
FORWARD X
REVERSE X Circuit diagram: -
005327
GEAR X Connection: -
Function: 2.8 Control system, transmission
Signal value:
1 Output signal for travel direction forward active.
0 No output signal.

66 8 Control system – 8.4.7.4 TRANSM, menu 4
PRESENT VALUE, REVERSE

page
–
Description: Status for rearward direction of travel from transmission

control unit (D793). Indicates if rearward drive is activated in the trans-
mission.
Circuit diagram: -
Connection: -
Signal value:
1 Output signal for travel direction reverse active.
0 No output signal.
PRESENT VALUE, GEAR

page
–
Description: Current gear, status from transmission control unit

(D793). Shows which gear is activated in the transmission.
Circuit diagram: -
Connection: -
Signal value: X = current gear.

OPERATING STATE, AUT/MAN MODE
page
–
Description: Shows which shifting program is selected automatic or

DIAG TRANSM. 4(X) manual.
OPERATING STATE
AUT/MAN MODE X Circuit diagram: -
WARNING X Connection: -
005328
OPERATING MODE X
Signal value:
1 Automatic.
0 Manual.
OPERATING STATE, WARNING

page
–
Description: Warning for serious malfunction in transmission from

Circuit diagram: -
Connection: -
Signal value:
1 Active error.
0 No errors.

OPERATING STATE, OPERATING MODE

page
–
Description: Operating mode status for transmission control unit

(D793); also shown in control unit display.
Circuit diagram: -
Connection: -
Signal value:
0 Not used.
1 Manual or automatic shifting, standard mode shown during

operation.
2 Not used.
3 Not used.
4 Limp home, reduced capacity due to malfunction in transmis-

sion.
5 Shut down, serious transmission malfunction control unit

shuts down, likely that malfunction cannot be shown as CAN-
bus.
6 Calibration of transmission in progress.

OPERATING STATE, SHIFT IN PROGRESS
page
–
Description: Status for transmission function during operation, shifting

DIAG TRANSM. 5(X) in progress. Active during shifting.
OPERATING STATE
SHIFT IN PROGRESS X Circuit diagram: -
FAULT X Connection: -
005329
OLD FAULT X
Signal value:
1 Shifting in progress.
0 No activity.
OPERATING STATE, FAULT

page
–
Description: Status for transmission’s function during operation, active

error codes present.
Circuit diagram: -
Connection: -
Signal value:
1 Active error code.
0 No error codes.

OPERATING STATE, OLD FAULT

page
–
Description: Status for transmission’s function during operation, there

are inactive error codes that have not been acknowledged.
Circuit diagram: -
Connection: -
Signal value:
1 There are inactive error codes that have not been acknowl-
edged.
0 No unacknowledged error codes.

DRUM SPEED
page
–
Description: Signal from sensor rpm drum (position 1).

DIAG TRANSM. 6(X)
DRUM SPEED XXXXHz
OUTPUT SPEED XXXXHz Connection: signal from B752 till D793/B3 and D793/C3
ENGINE SPEED XXXXHz
Function: 2.3.7 Sensor rpm drum
TURBINE SPEED XXXXHz
Signal value: XXXXHz = frequency, indicates pulses from the sensor
in Hz (pulses /second). To convert to rpm, divide frequency by number
1 2 3
of teeth on drum gear.
5
005330
4
1. Sensor, drum rpm (B752)
2. Temperature monitor torque converter (S221)
3. Sensor engine rpm and temperature transmission
(B758/766)
4. Sensor rpm turbine transmission (B751)
5. Sensor rpm output shaft (B758)
OUTPUT SPEED
page
–
Description: Signal from sensor rpm output shaft (propeller shaft) (po-
sition 5).
Connection: signal from B758 till D793/ D3 and D793/ E3
Function: 2.3.9 Sensor rpm output shaft
of teeth on output shaft’s gear.

ENGINE SPEED
page
–
Description: Rpm signal from sensor rpm engine speed (position 3).
Connection: signal from B758/766 to D793/H3
of teeth on input shaft’s gear.
TURBINE SPEED
page
–
Description: Signal from sensor rpm turbine transmission (position 4).

Connection: signal from B751 to D793/ R2
Function: 2.3.6 Sensor rpm turbine
of teeth on turbine’s gear.

OUTPUT STATUS, RSP DRIVE
page
–
Description: Status high and low side for control of solenoid valve RSP
DIAG TRANSM. 7(X) Drive.
OUTPUT STATUS
RSP DRIVE X X Circuit diagram: Circuit 2.0-2A3
2/4 VFS SELECTION X Connection: signal from D793/K1 and D793/K2 to Y6066
005331
1/3 VFS SELECTION X

11 Activated high and low side.
10 High side activated, low side no signal.
01 High side no signal, low side activated.
00 No signal.
OUTPUT STATUS, 2/4 VFS SELECTION

page
–
Description: Status of feed to solenoid valve VFS 2ND/4TH.

Connection: digital out from D793/ D1 and D793/ E1 to Y6069
Signal value:
1 Activated.
0 No signal.

OUTPUT STATUS, 1/3 VFS SELECTION

page
–
Description: Status of feed to solenoid valve VFS 1 ST/3 RD.

Connection: signal from D793/ H1 and D793/ J1 to Y6067
Signal value:
1 Activated.
0 No signal.

FWD SUPPLY
page
–
Description: Status for control current to clutch pack forward.

DIAG TRANSM. 8(X)
FWD SUPPLY X
REV SUPPLY X Connection: signal from D793/B1 to Y630
2/4 SUPPLY X
Function: 2.3.5 Valve block, transmission control, 2.8 Control system,
005332
1/3 SUPPLY X
transmission
Signal value:
1 Activated.
0 No signal.
REV SUPPLY
page
–
Description: Status for control current to clutch pack reverse.

Connection: signal from D793/F1 to Y631
transmission
Signal value:
1 Activated.
0 No signal.
2/4 SUPPLY
page
–
Description: Status for control current to clutch pack 2/4.

Connection: signal from D793/E2 to Y6074
transmission
Signal value:
1 Activated.
0 No signal.

1/3 SUPPLY
page
–
Description: Status for control current to clutch pack 1/3.

transmission
Signal value:
1 Activated.
0 No signal.

FWD FEEDBACK
page
–
Description: Present control current to solenoid valve clutch pack for-

DIAG TRANSM. 9(X) ward.
FWD FEEDBACK XXXXmA
REV FEEDBACK XXXXmA Circuit diagram: Circuit 2.0-2A3
2/4 FEEDBACK XXXXmA Connection: signal from D793/B1 to Y630
005333
1/3 FEEDBACK XXXXmA

transmission
Signal value: XXXX = Measured value in mA.
REV FEEDBACK
page
–
Description: Present control current to solenoid valve clutch pack re-

verse
transmission
2/4 FEEDBACK
page
–
Description: Present control current to solenoid valve clutch pack 2/4.

Connection: signal from D793/D1 to Y6069
transmission
1/3 FEEDBACK
page
–
Description: Present control current to solenoid valve clutch assembly

1/3.
Connection: signal from D793/H1 to Y6067
transmission


PRESENT SENSOR INPUT, PRESS FEEDB.
page
–
Description: Signal from sensor oil pressure in transmission. The

DIAG TRANSM. 10(X) transmission uses a pressure-sensitive make-contact and two resis-
PRESENT SENSOR INPUT tors in the cable harness to generate different voltage levels.
PRESS FEEDB XXXXohm
TRANSM.TEMP XXXXXmV Circuit diagram: Circuit 2.0-2A2
008900
CONV OUT TEMP XXXXXmV Connection: signal from "pressure feedback sensor" to D793/A2
Function: 2.6.2 Sensor oil pressure
Signal value:
0-1000 mV Short-circuiting to ground.
1500-2500 mV Oil pressure is correct.
2500-4000 mV Oil pressure is low.
4500-8000 mV Open circuit.
Over 8000 mV Short-circuiting to voltage.
PRESENT SENSOR INPUT, TRANS.TEMP

page
–
Description: Signal from sensor transmission oil temperature.

Connection: signal from B758/766 to D793/H3
Signal value: XXXX mV = signal voltage in mV (0-5000mV).
PRESENT SENSOR INPUT, CONV. OUT TEMP

page
–
Description: Signal from oil temperature sensor out from the transmis-
sion to the radiator. The transmission uses a temperature-sensitive
NO contact and two resistors in the cable harness to generate different
voltage levels.
Connection: signal from S221 to D793/J3
Function: 2.7.4 Sensor oil temperature oil cooler
Signal value:
0 mV Transmission oil has operating temperature.
2500 mV Transmission oil temperature is low.


AXLE RATIO
page
–
Description: Drive axle gear ratio.

DIAG TRANSM. 11(X)
Circuit diagram: -
PRESENT VALUE
AXLE RATIO XXXXX Connection: -
RADIUS XXXX
005335
Signal value: XXXXX = drive axle’s total gear ratio x 1024.
RADIUS
page
–
Description: Drive wheels’ radius.

Circuit diagram: -
Connection: -
Signal value: XXXX = Drive wheels’ radius in mm.

SPEED LIMIT, CAB
page
–
Description: Speed limitation from D790-1, e.g. emergency stop

DIAG TRANSM. 12(X) switch activated, reversible operator’s seat out of position or constant
SPEED LIMIT speed limitation.
SPD GEAR LOG
CAB XX X XX Circuit diagram: -
005336
FRAME XX X XX Connection: -
Function: 8.2.3 Speed limitation
Signal value:
SPD, XX = speed in km/h.
GEAR, X = current gear.
LOG, XX = code which specifies what has caused the speed lim-
itation.
SPEED LIMIT, FRAME

page
–
Description: Speed limitation from D797-1 or D797-2, e.g. cab tilted,

load not in transport position during transport.
Circuit diagram: -
Connection: -
Function: 8.2.3 Speed limitation
Signal value:
SPD, XX = speed in km/h.
GEAR, X = current gear.
LOG, XX = code which specifies what has caused the speed lim-
itation.


ACT ERROR AREA
page
–
Description: Indicates malfunction area active error, first part of the er-
DIAG TRANSM. 13(X) ror code. In case of several error codes, the most serious error code
ACT ERROR AREA XXX is shown.
TYPE XXX
NUMBER OF OCCU. XXXXX Circuit diagram: -
005337
TIME AGO XXXXX Connection: -
Signal value: XXX = First part of error code; see section D Error codes.

TYPE
page
–
Description: Indicates type of active error.

Circuit diagram: -
Connection: -
Signal value: XXX = Second part of error code.
NUMBER OF OCCU.
page
–
Description: Number of times active errors have occurred.

Circuit diagram: -
Connection: -
Signal value: XXXXX = Number of times active errors have occurred.
TIME AGO
page
–
Description: When latest active error occurred.

Circuit diagram: -
Connection: -
Signal value: XXXXX = Operating time in hours since latest error.

CONVERTER STATUS (Nm), TORQUE IMPELLER
page
–
Description: Torque transmitted by from engine to impeller in torque

DIAG TRANSM. 14(X) converter. The torque absorbed by the transmission.
CONVERTER STATUS (Nm)
TORQUE IMPELLER XXXX Circuit diagram: -
TORQUE TURBINE XXXX Connection: -
007622

Signal value: XXXX = Torque in Nm.
CONVERTER STATUS (Nm), TORQUE TURBINE

page
–
Description: Current torque transmitted by torque converter to trans-

mission.
Circuit diagram: -
Connection: -
Signal value: XXXX = Torque in Nm.

76 8 Control system – 8.4.8 ELSERV
8.4.8 ELSERV
ELSERV, description
page
–
DIAGNOSIS
CAN/POWER LIGHTS CAB This group covers electric servo functions.
CLIMATE HYD ENGINE
Confirm selection with function key for Enter.
005400
OLS EXTRA

PRESENT INPUT SIGNALS, P1
page
–
Description: Signal from control lever P1.

DIAG ELSERVO 1(X)
PRESENT INPUT SIGNALS
P1 XX.XXV Connection: signal from R8071/3 (S815/8) to analogue in D790-1/K7:3
P2 XX.XXV
Function: 7.1.1 Control levers
005401
P3 XX.XXV
Signal value: XX.XXV = 0,50 - 4,50 V. 2,5 V in zero position.

page
–

Connection: signal from R8072/3 (S815/4) to analogue in D790-1/K7:4

page
–

Connection: signal from R8073/3 (S815/11) to analogue in D790-1/
K7:5

page
–

DIAG ELSERVO 2(X)
P4 XX.XXV Connection: signal from R8074/3 (S815/1) to analogue in D790-1/K7:6
P7 XX.XXV
005402
P5 XX.XXV

page
–

Connection: signal from R8075-2/3 to analogue in D790-1/K9:9

8 Control system – 8.4.8.3 ELSERV, menu 3 77

page
–


OUTPUT LIFT, REFERENCE
page
–
Description: Status for control current to control valve (solenoid valve,

DIAG ELSERVO 3(X) lift mast).
OUTPUT LIFT
REFERENCE XY Circuit diagram: Circuit 7.2-1
REQUIRED VALUE XXXmA Connection: digital out from D797-1/K1:4 to Y6005/1 (Y6005-1/1 on
005403
FEEDBACK XXXmA machines with freelift).

Function: 7.2.5 Control valve, lift and tilt (DCF360-450CSG and DCF
90-100)
7.2.6 Load handling control valve (DCF280-500)
Signal value:
00 No output signal, PWM off.
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
OUTPUT LIFT, REQUIRED VALUE

page
–
Description: Reference value for control current to control valve, (so-

lenoid valve, lift mast).
Connection: output signal, reference value out from D797-1/K1:16 to
Y6005/2 (Y6005-1/2 on machines with freelift).
90-100)
Signal value: XXX = Current value: in mA for control of solenoid valve.

78 8 Control system – 8.4.8.4 ELSERV, menu 4
OUTPUT LIFT, FEEDBACK

page
–
Description: Present control current to control valve (solenoid valve, lift

mast).
Connection: output signal, actual value out from D797-1/K1:16 to
90-100)
Signal value: XXX = Measured current value in mA.

OUTPUT LOWER, REFERENCE
page
–

DIAG ELSERVO 4(X) lower mast).
OUTPUT LOWER
REQUIRED VALUE XXXmA Connection: digital out from D797-1/K1:4 to Y6004/1 (Y6004-1/1 on
005404
FEEDBACK XXXmA machines with freelift).

90-100)
Signal value:
NOTE
OUTPUT LOWER, REQUIRED VALUE

page
–
Description: Reference value for control current to control valve (sole-

noid valve, lower mast)
90-100)

OUTPUT LOWER, FEEDBACK

page
–
Description: Present control current to control valve (solenoid valve,

lower mast).
90-100)

OUTPUT TILT IN, REFERENCE
page
–

DIAG ELSERVO 5(X) tilt in).
OUTPUT TILT IN
REQUIRED VALUE XXXmA Connection: digital out from D797-1/K1:5 to Y6011/1
005405
FEEDBACK XXXmA
90-100)
Signal value:
NOTE
OUTPUT TILT IN, REQUIRED VALUE

page
–
Description: Reference value for control current to control valve (sole-

noid valve, tilt in).
Connection: output signal reference value out from D797-1/K1:18 to
Y6011/2
90-100)

OUTPUT TILT IN, FEEDBACK

page
–
Description: Present for control current to control valve (solenoid

valve, tilt in).
Y6011/2
90-100)

OUTPUT TILT OUT, REFERENCE
page
–

DIAG ELSERVO 6(X) tilt out).
OUTPUT TILT OUT
005406
FEEDBACK XXXmA
90-100)
Signal value:
NOTE
OUTPUT TILT OUT, REQUIRED VALUE

page
–
Description: Reference value for control current to control valve, (so-

lenoid valve, tilt out).
Connection: output signal, reference value out from D797-1/K1:19, to
solenoid valve Y6010/1
90-100)

OUTPUT TILT OUT, FEEDBACK

page
–
Description: Present control current to control valve (solenoid valve, tilt

out).
Connection: output signal, actual value out from D797-1/K1:19 to so-
lenoid valve Y6010/2
90-100)

OUTPUT SIDE SHIFT LE, REFERENCE
page
–
Description: Status for control current to control valve, load handling

DIAG ELSERVO 7(X) (solenoid valve, side shift left).
OUTPUT SIDESHIFT LE
005407
FEEDBACK XXXmA
Function: 7.4.5 Load handling control valve (DCF280-500)
Signal value:
NOTE
OUTPUT SIDE SHIFT LE, REQUIRED VALUE

page
–
Description: Reference value for control current to control valve for

load handling (solenoid valve, side shift left).
Y6020/2
OUTPUT SIDE SHIFT LE, FEEDBACK

page
–
Description: Present control current to control valve, load handling (so-

lenoid valve, side shift left).
Y6020/2


OUTPUT SIDE SHIFT RI, REFERENCE
page
–

DIAG ELSERVO 8(X) (solenoid valve, side shift right).
OUTPUT SIDESHIFT RI
005408
FEEDBACK XXXmA
Signal value:
NOTE
OUTPUT SIDE SHIFT RI, REQUIRED VALUE

page
–

load handling (solenoid valve, side shift right).
Y6021/2
OUTPUT SIDE SHIFT RI, FEEDBACK

page
–

lenoid valve, side shift right).
Y6021/2


OUTPUT SPREADING IN, REFERENCE
page
–

DIAG ELSERVO 9(X) (solenoid valve, spreading left).
OUTPUT SPREADING IN
005409
FEEDBACK XXXmA
Signal value:
NOTE
OUTPUT SPREADING IN, REQUIRED VALUE

page
–
Description: Reference value for control current to control valve, load

handling (solenoid valve, spreading in).
Y6019/2
OUTPUT SPREADING IN, FEEDBACK

page
–

lenoid valve, spreading in).
Y6019/2


OUTPUT SPREADING OUT, REFERENCE
page
–

DIAG ELSERVO 10(X) (solenoid valve, spreading out).
OUTPUT SPREADING OUT
005410
FEEDBACK XXXmA
Signal value:
NOTE
OUTPUT SPREADING OUT, REQUIRED VALUE

page
–

handling (solenoid valve, spreading out).
Y6018/2
OUTPUT SPREADING OUT, FEEDBACK

page
–

lenoid valve, spreading out).
Y6018/2


OUTPUT LIFT 2, REFERENCE
page
–

DIAG ELSERVO 11(X) (solenoid valve, lift carriage).
OUTPUT LIFT 2
005411
FEEDBACK XXXmA
Signal value:
NOTE
OUTPUT LIFT 2, REQUIRED VALUE

page
–

handling (solenoid valve, lift carriage).
Y6022/2
OUTPUT LIFT 2, FEEDBACK

page
–

lenoid valve, lift carriage).
Y6022/2


OUTPUT LOWER 2, REFERENCE
page
–

DIAG ELSERVO 12(X) (solenoid valve, lower carriage).
OUTPUT LOWER 2
005412
FEEDBACK XXXmA
Signal value:
NOTE
OUTPUT LOWER 2, REQUIRED VALUE

page
–

handling (solenoid valve, lower carriage).
Y6023/2
OUTPUT LOWER 2, FEEDBACK

page
–

lenoid valve, lower carriage).
Y6023/2

PRESENT INPUT SIGNALS, SPREADER
page
–
Description: Signal from switch for spreading the attachment.

DIAG ELSERVO 13(X) Circuit diagram: Circuit 7.0-2
SPREADER IN X OUT X Connection:
PISTOL X
IN: Signal from S815/14 to digital in D790-1/K7:14 (spreading in)
007128
UNLOCK TW X
OUT: Signal from S815/16 to digital in D790-1/K7:13 (spreading
out)

Function: 7.1.1 Control lever

Signal value:
0 No signal.
PRESENT INPUT SIGNALS, PISTOL

page
–
Description: Signals from control lever for pistol trigger.

Connection: from S815/19 to digital in D790-1/K7:16
Signal value:
0 No signal.
PRESENT INPUT SIGNALS, UNLOCK TW

page
–
Description: Signal from control lever to unlock twistlock.

Signal value:
0 No signal.

PRESENT INPUT SIGNALS, OPTION LOCKING
page
–
Description: Signal from control lever for option locking.

DIAG ELSERVO 14(X)
OPTION LOCKING X Connection: signal from S815/18 to digital in D790-1/K8:2
LEVELLING LOCKING X
007129
Signal value:
0 No signal.

PRESENT INPUT SIGNALS, LEVELLING LOCKING

page
–
Description: Signal from control lever fir levelling locking.

Signal value:
0 No signal.

REGENERATION STATUS, INPUT DAMPING
page
–
Description: Signal from position sensor, end position, regeneration.

DIAG ELSERVO 15(X)
REGENERATION STATUS
INPUT DAMPING X Connection: Signal from B7211-2 to digital in D797-2/K1:24.
OUTPUT LEFT XY
Function: 7.2.10 Mast position sensor (DCF360-450CSG)
005415
OUTPUT RIGHT XY
Signal value:
0 No signal.
REGENERATION STATUS, OUTPUT LEFT

page
–
Description: Power supply to solenoid valve, regeneration, left.

Connection: Signal from D797-1/K1:12 to Y6052/1
Function: 7.2.6 Valve block, lift cylinder (DCF360-450CSG)
Signal value:

tive.


8 Control system – 8.4.9 ATTACH, DCF360-450CSG 89
REGENERATION STATUS, OUTPUT RIGHT

page
–
Description: Power supply to solenoid valve, regeneration, right.

Connection: Signal from D797-1/K1:11 to Y6051/1
Function: 7.2.6 Valve block, lift cylinder (DCF360-450CSG)
Signal value:

tive.

8.4.9 ATTACH, DCF360-450CSG

ATTACH, description
page
–
This group covers attachment functions.

DIAGNOSIS
CLIMATE HYD ENGINE
005339
OLS EXTRA
8.4.9.1 ATTACH, menu 1

page
–

DIAG ATTACHMENT 1(X)
P3 XX.XXV Connection: signal from R8073/3 (S815/11) to analogue in D790-1/
P4 XX.XXV K7:5
005416
P7 XX.XXV

page
–


page
–


90 8 Control system – 8.4.9.2 ATTACH, menu 2


page
–

P5 XX.XXV Connection: signal from R8075-1/3 to analogue in D790-1/K7:7
005417

page
–
Description: Signals from switch for spreading the attachment.

DIAG ATTACHMENT 3(X) Circuit diagram: Circuits 7.5-1, 7.0-2
AUTO 20/40 X IN: Signal from S1012/1 (S815/14) to digital in D790-1/K7:14
005418
30/35 STOP X
(spreading in)
OUT: Signal from S1012/7 (S815/16) to digital in D790-1/K7:13
(spreading out)
Function: 7.1.3 Switch, spreading 20’-40’, 7.1.1 Control lever
Signal value:
0 No signal.
PRESENT INPUT SIGNALS, AUTO 20/40

page
–
Description: Signal from switch automatic spreading 20/40.

Connection: from S1012-2/1 to digital in D790-1/K8:11
Function: 7.5 Spreading
Signal value:
0 No signal.

8 Control system – 8.4.9.4 ATTACH, menu 4 91
PRESENT INPUT SIGNALS, 30/35 STOP

page
–
Description: Signal from switch for stop at 30’/35’.

Signal value:
0 No signal.

page
–

DIAG ATTACHMENT 4(X) Circuit diagram: Circuit 7.0-2
PISTOL X Function: 7.1.1 Control lever
007130
Signal value:

0 No signal.

PRESENT INPUT SIGNALS, LOCK TWISTLOCK
page
–
Description: Signal from switch lock twistlock.

LOCK TWISTLOCK X Connection: signal from S1003/7 and S1007/2 to digital in D790-1/
UNLOCK TWISTLOCK X K8:12
005420
LOCK LEVELLING X
Function: 7.9.1 Twistlocks
Signal value:

0 No signal.
PRESENT INPUT SIGNALS, UNLOCK TWISTLOCK

page
–
Description: Signal from control lever to unlock twistlock.

Connection: signal from S1002/1 (S815/20) to digital in D790-1/K7:15
Signal value:

0 No signal.

PRESENT INPUT SIGNALS, LOCK LEVELLING

page
–
Description: Signal from switch for levelling lock.

Function: 7.8 Levelling, 7.1.1 Control levers
Signal value:
0 No signal.

PRESENT INPUT SIGNALS, LOW SPEED 20/40
page
–
Description: Signal from spreading position sensor for end position

DIAG ATTACHMENT 6(X) damping 20’/40’.
LOW SPEED 20/40 X Connection: from inductive sensor B769-1/C to digital in D791-1/K1:12
008902
30/35 STOP X
Function: 7.5.8 Position sensor spreading
Signal value:
0 No signal.

page
–
Description: Signal from spreading position sensor for stop at 30’/35’.

Connection: from inductive sensor B777-1/C to digital in D791-1/K1:20
Signal value:
0 No signal.

PRESENT INPUT SIGNALS, ALIGNMENT LE RI, FRONT
page
–
Description: Signals from sensors alignment right front and left front.
ALIGNMENT LE RI Connection:
FRONT X X
LE: signal from B7202L/C to digital in D791-1/K1:13
005422
REAR X X
RI: signal from B7202R/C to digital in D791-1/K1:40

Function: 7.9.1.6 Alignment sensor

Signal value:
0 No signal.
PRESENT INPUT SIGNALS, ALIGNMENT LE RI, REAR

page
–
Description: Signals from sensors alignment right rear and left rear.
Connection:
LE: signal from B7203L/B to digital in D791-1/K1:27
RI: Signal from B7203R/B to digital in D791-1/K1:26
Signal value:
0 No signal.

PRESENT INPUT SIGNAL LE RI, LOCKED TW
page
–
Description: Signals from sensors locked twistlock right and left.

LE RI Connection:
LOCKED TW X X
005423
UNLOCKED TW X X
Function: 7.9.1.7 Sensor twistlock
Signal value:
0 No signal.
PRESENT OUTPUT SIGNAL LE RI, UNLOCKED TW

page
–
Description: Signals from sensors open twistlock right and left.

Connection:
Function: 7.9.1.7 Sensor twistlock
Signal value:
0 No signal.


PRESENT OUTPUT SIGNAL, LOCK TW
page
–
Description: Voltage feed to attachment control valve, locked twist-

DIAG ATTACHMENT 9(X) lock.
LOCK TW XY Circuit diagram: Circuit 7.9-1
UNLOCK TW XY Connection: digital out from D791-1/K1:7 to /1
005424
Function: 7.9.1.2 Attachment control valve
Signal value:

tive.

PRESENT OUTPUT SIGNAL, UNLOCK TW

page
–
Description: Voltage feed to control valve attachment, open twistlock.

Connection: digital out from D791-1/K1:9 to Y6039/1
Function: 7.9.1.2 Attachment control valve
Signal value:

tive.


PRESENT OUTPUT SIGNAL, IND. LOCKED TW
page
–
Description: Voltage feed, indicator light for locked twistlock - located

DIAG ATTACHMENT 10(X) on carriage.
IND. LOCKED TW XY Circuit diagram: Circuit 7.9-1
IND. UNLOCKED TW XY Connection: digital out from D791-1/K1:29 to H563/1
005425
IND. ALIGNMENT XY


Signal value:

tive.

PRESENT OUTPUT SIGNAL, IND. UNLOCKED TW

page
–
Description: Voltage feed, indicator light for open twistlock - located on

carriage.
Connection: digital out from D791-1/K1:25 to H562/1
Signal value:

tive.

PRESENT OUTPUT SIGNAL, ALIGNMENT

page
–
Description: Voltage feed, alignment indicator light - located on car-

riage.
Signal value:

tive.



page
–
Description: Status for control current to attachment control valve for

DIAG ATTACHMENT 11(X) side shift left.
OUTPUT SIDESHIFT LE
005426
FEEDBACK XXXmA
Function: 7.4.2 Control valve attachment
Signal value:
NOTE

page
–
Description: Reference value for control current to attachment control

valve for output signal, side shift left.
Y6020/2

page
–
Description: Present control current to attachment control valve for

side shift left.
Connection: output signal actual value out from D791-1/K1:18 to
Y6020/2


page
–

DIAG ATTACHMENT 12(X) side shift right.
OUTPUT SIDESHIFT RI
REQUIRED VALUE XXXmA Connection: digital out from D791/K1:33 to Y6021/1
005427
FEEDBACK XXXmA
Signal value:
NOTE

page
–

valve for output signal, side shift right.
Y6021/2

page
–

side shift right.
Y6019/2

OUTPUT SPREADER OUT, REFERENCE
page
–
Description: Status control current to control valve attachment for

DIAG ATTACHMENT 13(X) spreader out 20/40.
OUTPUT SPREADER OUT
REFERENCE XY
REQUIRED VALUE XXXmA
005428
FEEDBACK XXXmA


Signal value:

NOTE
OUTPUT SPREADER OUT, REQUIRED VALUE

page
–

valve for output signal, spreading out 20/40.
Y6018/2
OUTPUT SPREADER OUT, FEEDBACK

page
–
Description: Present control current to control valve attachment for

spreader out 20/40.
Y6018/2

OUTPUT SPREADER IN, REFERENCE
page
–
Description: Status control current to control valve attachment for

DIAG ATTACHMENT 14(X) spreader in 40/20.
OUTPUT SPREADER IN
005429
FEEDBACK XXXmA
Signal value:


NOTE
OUTPUT SPREADER IN, REQUIRED VALUE

page
–

valve for output signal, spreading in 40/20.
Y6019/2
OUTPUT SPREADER IN, FEEDBACK

page
–

spreader in 40/20.
Y6019/2

PRESENT OUTPUT SIGNAL, UNLOCK LEVELLING
page
–
Description: Voltage feed to levelling solenoid valve.

UNLOCK LEVELLING XY Connection: digital out from D791-1/K1:42 to Y637-1/1 and Y637-2/1
Function: 7.8.4 Valve block, levelling cylinders
005430
Signal value:

tive.


OUTPUT LEVELLING, CLOCKWISE
page
–
Description: Voltage feed to attachment control valve, clockwise level-

DIAG ATTACHMENT 16(X) ling.
OUTPUT LEVELLING
CLOCKWISE XY Circuit diagram: Circuit 7.8-1
COUNTERCLOCKWISE XY Connection: digital out from D791-1/K1:30 to Y6036/1
005431


Signal value:


OUTPUT LEVELLING, COUNTERCLOCKWISE

page
–
Description: Voltage feed to attachment control valve, counterclock-

wise levelling.
Signal value:



OUTPUT PROJECT LE OUT, REFERENCE
page
–

DIAG ATTACHMENT 17(X) extension, left side, out.
OUTPUT PROJECT LE OUT
REQUIRED VALUE XXXmA Connection: digital out from D791-1/K1:3 to Y6046-2/1
005432
FEEDBACK XXXmA
Signal value:
NOTE

OUTPUT PROJECT LE OUT, REQUIRED VALUE

page
–

valve for output signal, extension, left side out
Y6046-2/2
OUTPUT PROJECT LE OUT, FEEDBACK

page
–
Description: Present control current to attachment control valve for ex-

tension, left side out.
Y6046-2/2

OUTPUT PROJECT LE IN, REFERENCE
page
–

DIAG ATTACHMENT 18(X) extension, left side in.
OUTPUT PROJECT LE IN
005433
FEEDBACK XXXmA
Signal value:
NOTE
OUTPUT PROJECT LE IN, REQUIRED VALUE

page
–

valve for output signal, extension, left side in.
Y6046-1/2

OUTPUT PROJECT LE IN, FEEDBACK

page
–

tension, left side in.
Y6046-1/2

OUTPUT PROJECT RI OUT, REFERENCE
page
–

DIAG ATTACHMENT 19(X) extension, right side out.
OUTPUT PROJECT RI OUT
005434
FEEDBACK XXXmA
Signal value:
NOTE
OUTPUT PROJECT RI OUT, REQUIRED VALUE

page
–

valve for output signal, extension, right side out
Y6046-4/2
OUTPUT PROJECT RI OUT, FEEDBACK

page
–

tension, right side out.
Y6046-4/2


OUTPUT PROJECT RI IN, REFERENCE
page
–

DIAG ATTACHMENT 20(X) extension, right side in.
OUTPUT PROJECT RI IN
005435
FEEDBACK XXXmA
Signal value:
NOTE
OUTPUT PROJECT RI IN, REQUIRED VALUE

page
–

valve for output signal, extension, right side in.
Y6046-3/2
OUTPUT PROJECT RI IN, FEEDBACK

page
–

tension, right side in.
Y6046-3/2


PRESENT OUTPUT SIGNAL, BUZZER AUTO 20-40
page
–

PRESENT OUTPUT SIGNAL Description: Voltage feed to buzzer automatic spreading 20’-40’.
Circuit diagram: Circuit 7.5.3
BUZZER AUTO 20-40 XY
009181
Signal value:

signal is active.
8.4.9 ATTACH, DCF 90-100 with lifting hook

attachment
ATTACH, description
page
–

DIAGNOSIS
CLIMATE HYD ENGINE
005339
OLS EXTRA

page
–

P4 XX.XXV K7:5
005416
P7 XX.XXV

page
–



page
–


page
–

005417

page
–

AUTO 20/40 X IN: Signal from S1012/1 (S815/14) to digital in D790/K7:14
005418
30/35 STOP X
(spreading in)
OUT: Signal from S1012/7 (S815/16) to digital in D790/K7:13
(spreading out)
Signal value:
0 No signal.

page
–

Signal value:
0 No signal.


page
–

Signal value:
0 No signal.

page
–

007130
Signal value:
0 No signal.

PRESENT INPUT SIGNALS, LOCK CONT
page
–
Description: Signal from switch, lock lock tongue.

LOCK CONT X Connection: signal from S1003 to digital in D790-1/K8:12
UNLOCK CONT X
Function: 7.9.2 Lifting hook
010079
Signal value:
0 No signal.
PRESENT INPUT SIGNALS, UNLOCK CONT

page
–
Description: Signal from control lever to open lock tongue.

Connection: signal from S1002 to digital in D790-1/K7:15
Signal value:
0 No signal.


page
–

DIAG ATTACHMENT 6(X) damping 20’/40’ right or left.
LE RI Circuit diagram: Circuit 5
LOW SPEED 20/40 X X Connection: from inductive sensor B769L to digital in D791/K1:12 or
010080
30/35 STOP X X from inductive sensor B769R to digital in D791/K1:40
Signal value:
0 No signal.

page
–
Description: Signal from position sensor for end position 30’ right or
left.
Circuit diagram: Circuit 5
Connection: from inductive sensor B777L to digital in D791/K1:20 or
from inductive sensor B777R to digital in D791/K1:37
Signal value:
0 No signal.

PRESENT INPUT SIGNALS, ALIGNMENT LE RI, UPPER
page
–
Description: Signals from sensors alignment right upper and left up-
DIAG ATTACHMENT 7(X) per.
ALIGNMENT LE RI Circuit diagram: Circuit 11B
UPPER X X Connection:
010081
LOWER X X
LE: signal from B7203RU-2 to digital in D791/K1:36
RI: Signal from B7203LU-2 to digital in D791/K1:11
Function: 7.9.2.8 Alignment and detection sensor
Signal value:
0 No signal.

PRESENT INPUT SIGNALS, ALIGNMENT LE RI, LOWER

page
–
Description: Signals from sensors alignment right lower and left lower.
Circuit diagram: Circuit 11B
Connection:
LE: signal from B7203LL to digital in D791/K1:27
RI: Signal from B7203RL to digital in D791/K1:26
Signal value:
0 No signal.

PRESENT INPUT SIGNAL LE RI, LOCKED CONT
page
–
Description: Signals from sensors locked lock tongue right and left.
LE RI Connection:
LOCKED CONT X X
010082
UNLOCKED CONT X X
Function: 7.9.2.9 Lock tongue sensor
Signal value:
0 No signal.
PRESENT OUTPUT SIGNAL LE RI, UNLOCKED CONT

page
–
Description: Signals from sensors open lock tongue right and left.
Connection:
LE: signal from B7204L to digital in D791-1/K1:22
RI: signal from B7204R to digital in D791-1/K1:41
Function: 7.9.2.9 Lock tongue sensor
Signal value:
0 No signal.


PRESENT OUTPUT SIGNAL, LOCK CONT
page
–
Description: Voltage feed to attachment control valve, locked lock

DIAG ATTACHMENT 9(X) tongues.
LOCK CONT XY Circuit diagram: Circuit 8
UNLOCK CONT XY Connection: digital out from D791/K1:7 to Y6040
010083
Signal value:


PRESENT OUTPUT SIGNAL, UNLOCK CONT

page
–
Description: Voltage feed to attachment control valve, open lock

tongues.
Connection: digital out from D791/K1:9 to Y6039
Signal value:




PRESENT OUTPUT SIGNAL, IND. LOCKED CONT
page
–
Description: Voltage feed, indicator light for locked lock tongues - lo-
DIAG ATTACHMENT 10(X) cated on carriage.
IND. LOCKED CONT XY Circuit diagram: Circuit 10A
IND. UNLOCKED CONT XY Connection: digital out from D791/K1:29 to H563
010084
IND. ALIGNMENT XY
Signal value:


PRESENT OUTPUT SIGNAL, IND. UNLOCKED CONT

page
–
Description: Voltage feed, indicator light for unlocked lock tongues - lo-
cated on carriage.
Circuit diagram: Circuit 10A
Connection: digital out from D791/K1:25 to H562
Signal value:




page
–

riage.
Signal value:



page
–

OUTPUT SIDESHIFT LE
REQUIRED VALUE XXX Connection: digital out from D791-1/K1:32 to Y6020/1
010088
FEEDBACK XXX
Signal value:
NOTE

page
–

Y6020/2


page
–

side shift left.
Y6020/2

page
–

OUTPUT SIDESHIFT RI
REQUIRED VALUE XXX Connection: digital out from D791/K1:33 to Y6021/1
010089
FEEDBACK XXX
Signal value:
NOTE

page
–

Y6021/2

page
–

side shift right.
Y6019/2


OUTPUT LEVELLING CW, REFERENCE
page
–
Description: Status control current to control valve attachment for lev-

DIAG ATTACHMENT 13(X) eling right.
OUTPUT LEVELLING CW
REFERENCE XY Circuit diagram: Circuit 6
REQUIRED VALUE XXX Connection: digital out from D791/K1:31 to Y6035
010085
FEEDBACK XXX
Signal value:
NOTE
OUTPUT LEVELLING CW, REQUIRED VALUE

page
–

valve for output signal, levelling right.
Connection: output signal reference value out from D791/K1:19 to
Y6035
OUTPUT LEVELLING CW, FEEDBACK

page
–

leveling right.
Connection: output signal, actual value out from D791/K1:19 to Y6035


OUTPUT LEVELLING CCW, REFERENCE
page
–

DIAG ATTACHMENT 14(X) eling left.
OUTPUT LEVELLING CW
010086
FEEDBACK XXX
Signal value:
NOTE
OUTPUT LEVELLING CCW, REQUIRED VALUE

page
–

valve for output signal, levelling left.
Connection: output signal, reference value out from D791/K1:19 to
Y6036
OUTPUT LEVELLING CCW, FEEDBACK

page
–

leveling left.


Not used.
page
–

NOT USED
010077
Not used.
page
–

NOT USED
010078

OUTPUT SPREAD LE OUT, REFERENCE
page
–

DIAG ATTACHMENT 17(X) spreading, left side out.
OUTPUT SPREAD LE OUT
REQUIRED VALUE XXX Connection: digital out from D791/K1:3 to Y6018L
010087
FEEDBACK XXX
Signal value:
NOTE
OUTPUT SPREAD LE OUT, REQUIRED VALUE

page
–

valve for output signal, spreading, left side out
Y6018L

OUTPUT SPREAD LE OUT, FEEDBACK

page
–

spreading, left side out
Connection: output signal, actual value out from D791/K1:16 to
Y6018L

OUTPUT SPREADER LE IN, REFERENCE
page
–

DIAG ATTACHMENT 18(X) spreading, left side in.
OUTPUT SPREADER LE IN
010090
FEEDBACK XXX
Signal value:
NOTE
OUTPUT SPREADER LE IN, REQUIRED VALUE

page
–

valve for output signal, spreading, left side in
Y6019L
OUTPUT SPREADER LE IN, FEEDBACK

page
–

spreading, left side in.
Y6019L


OUTPUT SPREAD RI OUT, REFERENCE
page
–

DIAG ATTACHMENT 19(X) spreading, right side out.
OUTPUT SPREAD RI OUT
REFERENCE XY
REQUIRED VALUE XXX Connection: digital out from D791/K1:5 to Y6018R
010091
FEEDBACK XXX
Signal value:
NOTE
OUTPUT SPREAD RI OUT, REQUIRED VALUE

page
–

valve for output signal, spreading, right side out
Y6018R
OUTPUT SPREAD RI OUT, FEEDBACK

page
–

spreading, right side out.
Y6018R


OUTPUT SPREADER RI IN, REFERENCE
page
–

DIAG ATTACHMENT 20(X) spreading, right side in.
OUTPUT SPREADER RI IN
010092
FEEDBACK XXX
Signal value:
NOTE
OUTPUT SPREADER RI IN, REQUIRED VALUE

page
–

valve for output signal, spreading, right side in.
Y6019R
OUTPUT SPREADER RI IN, FEEDBACK

page
–

spreading, right side in.
Y6019R


page
–

009181
Signal value:

signal is active.

PRESENT INPUT SIGNALS, DETECT UPPER CONT.
page
–
Description: Signals from detection sensor for upper container right

DIAG ATTACHMENT 22(X) (B7203 RU) and detection sensor for upper container left (B7203LU).
DETECT UPPER CONT. Circuit diagram: Circuit 11B
LE RI LE: signal from B7203LU to digital in D791-1/K1:13
010075
X X
RI: Signal from B7203RU to digital in D791-1/K1:21
Signal value:
0 No signal.

PRESENT OUTPUT SIGNAL, IND. UPPER ALIGNMENT
page
–
Description: Signals from alignment sensor right upper (B7203RU-2)

DIAG ATTACHMENT 23(X) and left upper (B7203LU-2).
IND. UPPER Circuit diagram: Circuit 11B
ALIGNMENT XY Connection:
010076
LE: signal from B7203LU-2 to digital in D791-1/K1:11

RI: Signal from B7203RU-2 to digital in D791-1/K1:36
Signal value:
0 No signal.

120 8 Control system – 8.4.9 ATTACH, DCF 90-100 with twistlock attachment
8.4.9 ATTACH, DCF 90-100 with twistlock

attachment
ATTACH, description
page
–

DIAGNOSIS
CLIMATE HYD ENGINE
005339
OLS EXTRA

page
–

P4 XX.XXV K7:5
005416
P7 XX.XXV

page
–


page
–


page
–

005417


page
–

AUTO 20/40 X IN: Signal from S1012/1 (S815/14) to digital in D790-1/K7:14
005418
30/35 STOP X
(spreading in)
OUT: Signal from S1012/7 (S815/16) to digital in D790-1/K7:13
(spreading out)
Signal value:
0 No signal.

page
–

Signal value:
0 No signal.

page
–

Signal value:
0 No signal.


page
–

007130
Signal value:
0 No signal.

PRESENT INPUT SIGNALS, LOCK CONT
page
–
Description: Signal from switch for locking twistlocks.

LOCK CONT X Connection: signal from S1003 to digital in D790-1/K8:12
UNLOCK CONT X
010079
Signal value:
0 No signal.
PRESENT INPUT SIGNALS, UNLOCK CONT

page
–
Description: Signal from control lever to open twistlocks.

Connection: signal from S1002 to digital in D790-1/K7:15
Signal value:
0 No signal.


page
–

DIAG ATTACHMENT 6(X) damping 20’/40’ right or left.
LE RI Circuit diagram: Circuit 5
LOW SPEED 20/40 X X Connection: from inductive sensor B769L to digital in D791/K1:12 or
010080
30/35 STOP X X from inductive sensor B769R to digital in D791/K1:40
Signal value:
0 No signal.

page
–
Description: Signal from position sensor for end position 30’/35’ right
or left.
Connection: from inductive sensor B777L to digital in D791/K1:20 or
from inductive sensor B777R to digital in D791/K1:37
Signal value:
0 No signal.

PRESENT INPUT SIGNALS, ALIGNMENT LE RI
page
–
Description: Signals from right and left alignment sensors.

ALIGNMENT LE RI Connection:
X X
LE: signal from B7203R to digital in D791/K1:26
010093
RI: signal from B7203L to digital in D791/K1:27

Signal value:
0 No signal.


PRESENT INPUT SIGNAL LE RI, LOCKED CONT
page
–
Description: Signals from sensors locked twistlock right and left.

LE RI Connection:
LOCKED CONT X X
010082
UNLOCKED CONT X X
Function: 7.9.1.8 Twistlocks sensor
Signal value:
0 No signal.
PRESENT OUTPUT SIGNAL LE RI, UNLOCKED CONT

page
–
Description: Signals from sensors open twistlock right and left.

Connection:
LE: signal from B7204L to digital in D791-1/K1:22
RI: signal from B7204R to digital in D791-1/K1:41
Function: 7.9.1.8 Twistlocks sensor
Signal value:
0 No signal.

PRESENT OUTPUT SIGNAL, LOCK CONT
page
–
Description: Voltage feed to attachment control valve, locked twist-

DIAG ATTACHMENT 9(X) locks.
LOCK CONT XY Circuit diagram: Circuit 8
UNLOCK CONT XY Connection: digital out from D791/K1:7 to Y6040
010083

Signal value:



PRESENT OUTPUT SIGNAL, UNLOCK CONT

page
–
Description: Voltage feed to attachment control valve, open twistlocks.

Connection: digital out from D791/K1:9 to Y6039
Signal value:



PRESENT OUTPUT SIGNAL, IND. LOCKED CONT
page
–
Description: Voltage feed, indicator light for locked twistlocks - located

DIAG ATTACHMENT 10(X) on carriage.
IND. LOCKED CONT XY Circuit diagram: Circuit 10A
IND. UNLOCKED CONT XY Connection: digital out from D791/K1:29 to H563
010084
IND. ALIGNMENT XY
Signal value:


PRESENT OUTPUT SIGNAL, IND. UNLOCKED CONT

page
–
Description: Voltage feed, indicator light for unlocked twistlocks - lo-

cated on carriage.


Signal value:



page
–

riage.
Signal value:



page
–

OUTPUT SIDESHIFT LE
010088
FEEDBACK XXX
Signal value:
NOTE


page
–

Y6020/2

page
–

side shift left.
Y6020/2

page
–

OUTPUT SIDESHIFT RI
REQUIRED VALUE XXX Connection: digital out from D791/K1:33 to Y6021/1
010089
FEEDBACK XXX
Signal value:
NOTE

page
–

Y6021/2


page
–

side shift right.
Y6019/2

OUTPUT LEVELLING CW, REFERENCE
page
–

DIAG ATTACHMENT 13(X) eling right.
OUTPUT LEVELLING CW
010085
FEEDBACK XXX
Signal value:
NOTE
OUTPUT LEVELLING CW, REQUIRED VALUE

page
–

valve for output signal, levelling right.
Connection: output signal reference value out from D791/K1:19 to
Y6035
OUTPUT LEVELLING CW, FEEDBACK

page
–

leveling right.


OUTPUT LEVELLING CCW, REFERENCE
page
–

DIAG ATTACHMENT 14(X) eling left.
OUTPUT LEVELLING CW
010086
FEEDBACK XXX
Signal value:
NOTE
OUTPUT LEVELLING CCW, REQUIRED VALUE

page
–

valve for output signal, levelling left.
Y6036
OUTPUT LEVELLING CCW, FEEDBACK

page
–

leveling left.


Not used.
page
–

NOT USED
010077
Not used.
page
–

NOT USED
010078

OUTPUT SPREAD LE OUT, REFERENCE
page
–

DIAG ATTACHMENT 17(X) spreading, left side out.
OUTPUT SPREAD LE OUT
010087
FEEDBACK XXX
Signal value:
NOTE
OUTPUT SPREAD LE OUT, REQUIRED VALUE

page
–

valve for output signal, spreading, left side out
Y6018L

OUTPUT SPREAD LE OUT, FEEDBACK

page
–

spreading, left side out
Y6018L

OUTPUT SPREADER LE IN, REFERENCE
page
–

DIAG ATTACHMENT 18(X) spreading, left side in.
OUTPUT SPREADER LE IN
010090
FEEDBACK XXX
Signal value:
NOTE
OUTPUT SPREADER LE IN, REQUIRED VALUE

page
–

valve for output signal, spreading, left side in
Y6019L
OUTPUT SPREADER LE IN, FEEDBACK

page
–

spreading, left side in.
Y6019L


OUTPUT SPREAD RI OUT, REFERENCE
page
–

DIAG ATTACHMENT 19(X) spreading, right side out.
OUTPUT SPREAD RI OUT
REFERENCE XY
010091
FEEDBACK XXX
Signal value:
NOTE
OUTPUT SPREAD RI OUT, REQUIRED VALUE

page
–

valve for output signal, spreading, right side out
Y6018R
OUTPUT SPREAD RI OUT, FEEDBACK

page
–

spreading, right side out.
Y6018R

OUTPUT SPREADER RI IN, REFERENCE
page
–

DIAG ATTACHMENT 20(X) spreading, right side in.
OUTPUT SPREADER RI IN
REFERENCE XY
REQUIRED VALUE XXX
010092
FEEDBACK XXX


Connection: digital out from D791/K1:4 to Y6019R
Signal value:
NOTE
OUTPUT SPREADER RI IN, REQUIRED VALUE

page
–

valve for output signal, spreading, right side in.
Y6019R
OUTPUT SPREADER RI IN, FEEDBACK

page
–

spreading, right side in.
Y6019R

page
–

009181

Signal value:

signal is active.

134 8 Control system – 8.4.10 OLS
8.4.10 OLS
OLS, description
page
–
DIAGNOSIS
CAN/POWER LIGHTS CAB This group covers overload protection functions.
CLIMATE HYD ENGINE
005436
OLS EXTRA
8.4.10.1 OLS, menu 1

PRESENT INPUT SIGNAL, LIFT CYLINDER
page
–
Description: Signal from hydraulic pressure sensor, lift cylinder. See

DIAG OLS 1(X) also HYDRAULIC PRESSURE, LIFT CYLINDER page 52 for pressure
PRESENT INPUT SIGNAL information.
LIFT CYLINDER X.XXV Circuit diagram: Circuit 8.2-2

005437
TILT CYLINDER X.XXV Connection: signal from B768-1/3 to analogue in D797-1/K1:21

Function: 7.2.8 Sensor hydraulic pressure lift cylinder
Signal value: X.XXV = 0.50-4.50 V = Hydraulic oil pressure, 0.50 V
corresponds to 0 MPa, 4.50 V corresponds to 25 MPa.
PRESENT INPUT SIGNAL, TILT CYLINDER

page
–
Description: Signal from hydraulic pressure sensor, lift cylinder (C+

piston side). See also HYDRAULIC PRESSURE, TILT CYLINDER
page 52 for pressure information.
Connection: signal from B768-2/3, analogue in D797-1/K1:22
Function: 7.7.8 Hydraulic pressure sensor, tilt cylinder
Signal value: X.XXV = 0.50-4.50 V = Hydraulic oil pressure, 0.50 V
corresponds to 0 MPa, 4.50 V corresponds to 25 MPa.
8.4.10.2 OLS, menu 2

PRESENT INPUT SIGNAL, BYPASS
page
–
Description: Signal from bypass switch.

DIAG OLS 2(X)
BY-PASS X
Function: 8.1.3 Bypass switch
005438
Signal value:
1 Input signal active. Signal is only active for max. 60 seconds.
0 No signal.

8 Control system – 8.4.10.3 OLS, menu 3 135
8.4.10.3 OLS, menu 3

VD VALUE
page
–
Description: Permitted load at load centre in question as per Vehicle

DIAG OLS 3(X) Data.
VD VALUE XXXXXkg
PRESENT LOAD XXXXXkg Circuit diagram: -
Connection: -
008903
MAST POS SENSOR X
Signal value: XXXXX = Weight, kg
PRESENT LOAD
page
–
Description: Calculated load.

Circuit diagram: -
Connection: -
Signal value: XXXXX = Weight, kg
MAST POS SENSOR

page
–
Applies to DCF360-450CSG with 14000 mm lift height.

Description: Signal from sensor for limiting lift over 13,000 mm for
loads over 30 metric tons.
Connection: signal from B7211-3/C to digital in D797-1/K1:37
Signal value:
0 No signal.
8.4.10.4 OLS, menu 4

PRESENT INPUT SIGNAL, TILT ANGLE LIM.
page
–
Not used.
PRESENT INPUT SIGNAL, HEIGHT LIM.

page
–
For DCF360-450CSG with 14000 mm lift height and machines

DIAG OLS 4(X) equipped with lift height indicator/lift height limitation.
TILT ANGLE LIM X Description: Signal from sensor for limiting lift or warning for lift over
HEIGHT LIM X XXXXX mm.
010621

Function: Lift height limitation
Signal value:
0 No signal.

136 8 Control system – 8.4.11 EXTRA
8.4.11 EXTRA
EXTRA, description
page
–
This menu consists of optional functions:

DIAGNOSIS
CAN/POWER LIGHTS CAB • Reversible operator’s seat, VBFS
CLIMATE HYD ENGINE • Lever steering or mini-wheel, EL-STEERING
• External attachment, EXT-ATTACH
005440
OLS EXTRA
• Freelift, FREELIFT
• Cab tipping, MOVE-CAB
• Auxiliary equipment, OPT
• Inputs and outputs, control units, I/O
• Remote machine interface, RMI
Confirm selection in main menu with function key for Enter.
8.4.11.1 VBFS
VBFS, description
page
–
DIAGNOSIS EXTRA
VBFS EL-STEERING This group covers reversible operator’s seat functions.
EXT-ATTACH FREELIFT
MOVE-CAB OPT I/O RMI
008904
VBFS, menu 1
page
–
PRESENT INPUT SIGNAL REVERSIBLE SEAT, SWITCH

CW
DIAG VBFS 1(X)

PRESENT INPUT SIGNAL Description: Signal from switch, reversible operator’s seat, clockwise
REVERSIBLE SEAT rotation.
SWITCH CW X
005561
SWITCH CCW X
Function: 9.3.9 Reversible operator’s seat
Signal value:
0 No signal.
PRESENT INPUT SIGNAL REVERSIBLE SEAT, SWITCH

CCW
Description: Signal from switch, reversible operator’s seat, counter-

clockwise rotation.

8 Control system – 8.4.11.1 VBFS 137

Signal value:
0 No signal.
VBFS, menu 2
page
–
PRESENT OUTPUT SIGNAL REVERSIBLE SEAT, SEAT

CW
DIAG VBFS 2(X)

PRESENT OUTPUT SIGNAL Description: Voltage feed to seat reversal control unit (clockwise rota-
REVERSIBLE SEAT tion).
SEAT CW XY
007131
SEAT CCW XY
Connection: digital out from D797-2/K1:29 to A798/6
Signal value:


PRESENT OUTPUT SIGNAL REVERSIBLE SEAT, SEAT

CCW
Description: Voltage feed to seat reversal control unit (counterclock-

wise rotation).
Signal value:



138 8 Control system – 8.4.11.1 VBFS
VBFS, menu 3
page
–
PRESENT INPUT SIGNAL SEAT SENSORS, SEAT POS

FRONT
DIAG VBFS 3(X)

PRESENT INPUT SIGNAL Description: Signal from sensor, reversible operator’s seat, forward.
SEAT SENSORS Circuit diagram: Circuit 9.3-3
SEAT POS FRONT X
005563
SEAT POS REAR X Connection: signal from S720-F/2 to digital in D790-1/K1:13
Signal value:
0 No signal.
PRESENT INPUT SIGNAL SEAT SENSORS, SEAT POS

REAR
Description: Signal from sensor, reversible operator’s seat, rearward.

Connection: signal from S720-R/2 to digital in D790-1/K1:20
Signal value:
0 No signal.
VBFS, menu 4
page
–
PRESENT INPUT SIGNAL, ACCELERATOR 2
DIAG VBFS 4(X)

PRESENT INPUT SIGNAL Description: Signal from switch for auxiliary accelerator pedal (re-
ACCELERATOR 2 X.XXV verse).
REQUIRED SPD PROC XXX
007623
REQUIRED SPD RPM XXXX

Connection: signal from B690-2/2 to analogue in D790-1/K6:12
Function: 1 Engine
Signal value: X.XXV = 0.50 - 4.50 V

PRESENT INPUT SIGNAL, REQUIRED SPD PROC
Description: Required engine speed (in percent) which is sent from the
cab control unit (D790-1) to the engine control unit (D794) via the CAN
bus drivetrain.
Circuit diagram: -
Connection: -
Function: 1.9 Engine control system
Signal value: XXX = 0-100%
PRESENT INPUT SIGNAL, REQUIRED SPD RPM
Description: Required engine speed in rpm which is sent from the cab
control unit (D790-1) to the engine control unit (D794) via the CAN bus
drivetrain.
Circuit diagram: -
Connection: -
Function: 1.9 Engine control system
Signal value: XXXX = 0-2010 rpm
VBFS, menu 5
page
–
PRESENT OUTPUT SIGNAL STEERING VALVE, VALVE

CAB FRONT
DIAG VBFS 5(X)

PRESENT OUTPUT SIGNAL Description: Voltage feed to directional control valve, reversible oper-
STEERING VALVE ator’s seat (forward).
VALVE CAB FRONT XY
005565
VALVE CAB REAR XY

Connection: digital out from D797-2/K1:9 to Y636-1/1
Function: 9.3.12 Directional valve, reversible operator’s seat
Signal value:



PRESENT OUTPUT SIGNAL STEERING VALVE, VALVE

CAB REAR
Description: Voltage feed to directional control valve, reversible oper-

ator’s seat (rearward).
Connection: digital out from D797-2/K1:10 to Y636-2/1
Function: 9.3.12 Directional valve, reversible operator’s seat
Signal value:

tive.

VBFS, menu 6
page
–
HEADLIGHTS REAR, SWITCH
DIAG VBFS 6(X)

HEAD LIGHTS REAR Description: Signal from headlights switch.
SWITCH X Circuit diagram: Circuit 9.6-4
HEAD LE/RI XY
005566
DIMMED LE/RI XY Connection: signal from S100/1 to digital in D790-1/K6:5

Function: 9.6.1 Headlights.
Signal value:
0 No signal.

HEADLIGHTS REAR, HEAD L/R
Description: Voltage feed to high beam rear

Connection: digital out from D797-2/K1:1 to E402L-2/1 and E402R-2/1
Signal value:


HEADLIGHTS REAR, DIMMED L/R
Description: Voltage feed to low beam rear.

Connection: digital out from D797-2/K1:15 to E401L/1 and E401R/1
Signal value:



VBFS, menu 7
page
–
PRESENT OUTPUT SIGNAL, TAIL LIGHT FRONT
DIAG VBFS 7(X)

PRESENT OUTPUT SIGNAL Description: Voltage feed to front tail lights.
TAILLIGHT FRONT Circuit diagram: Circuit 9.3-5
005567
FRONT LE/RI XY Connection: digital out from D797-2/K1:25 to H413L/1 and H413R/1
Function: 9.6.3 Rear lights
Signal value:


VBFS, menu 8
page
–
PRESENT OUTPUT SIGNAL, BRAKE LIGHT FRONT
DIAG VBFS 8(X)

PRESENT OUTPUT SIGNAL Description: Voltage feed to front brake lights.
BRAKE LIGHT FRONT Circuit diagram: Circuit 9.3-4
005568
FRONT LE XY RI XY Connection:
LE: digital out from D797-2/K1:37 to H410L/1
RI: digital out from D797-2/K1:36 to H410R/1
Function: 9.6.4 Brake lights
Signal value:



8 Control system – 8.4.11.2 EL-STEERING 143
VBFS, menu 9
page
–
PRESENT OUTPUT SIGNAL, REVERSIBLE SEAT,

RELEASE BRAKE
DIAG VBFS 9(X)

PRESENT OUTPUT SIGNAL Description: Voltage feed to brake solenoid valve, seat reversal. The
REVERSIBLE SEAT brake keeps the seat locked in position. The break is only released
RELEASE BRAKE XY when the stool is rotated.
008918
DAMP SPEED XY


PRESENT OUTPUT SIGNAL, REVERSIBLE SEAT, DAMP

SPEED
Description: Voltage feed to seat reversal control unit (speed damp-

ing).


8.4.11.2 EL-STEERING
EL-STEERING, description
page
–
DIAGNOSIS EXTRA
VBFS EL-STEERING This group handles functions for lever steering/mini-wheel steering.
EXT-ATTACH FREELIFT
008911

144 8 Control system – 8.4.11.2 EL-STEERING
EL-STEERING, menu 1
page
–
PRESENT INPUT SIGNAL, SIGNAL 1 P6

Description: Signal from mini-wheel (signal 1) or steering lever.
DIAG STEERING 1(X)
SIGNAL 1 P6 X.XXV Connection: signal from R825/H1 to digital in D790-1/K9:8
SIGNAL 2 P7 X.XXV
Function: 5.2 Power assisted system
005443
LOGIC X.XXV
Signal value, control lever: XX.XXV = 0.50 - 4.50 V
Signal value, mini-wheel: XX.XXV = 0 - 5 V
PRESENT INPUT SIGNAL, SIGNAL 2 P7

Description: Signal from mini-wheel (signal 2). (Only applies to mini-
wheel.)
Connection: signal from R825/H2 to digital in D790-1/K9:9
Signal value: XX.XXV = 0 - 5 V
PRESENT INPUT SIGNAL, LOGIC

Description: Signal from mini-wheel (signals 1 and 2). Indicates logical
value for mini-wheel. A high value indicates steering to the left. A low
value indicates steering to the right.
Connection: signal from R825/H1 to digital in D790-1/K9:8 and R825/
H2 to digital in D790-1/K9:9.
Signal value: XX.XXV = 0 - 5 V
EL-STEERING, menu 2
page
–
SWITCHES, ON/OFF
Description: Signal from switch mini-wheel/steering lever.
DIAG STEERING 2(X)
SWITCHES
ON/OFF X Connection: signal from S113/1 to digital in D790-1/K9:5
FORWARD X
005569
REVERSE X
Signal value:
0 No signal.

SWITCHES, FORWARD
Description: Signal from mini-wheel or steering lever (travel direction
selector forward).
Signal value:
0 No signal.
SWITCHES, REVERSE
Description: Signal from mini-wheel or steering lever (travel direction
selector reverse).
Signal value:
0 No signal.
EL-STEERING, menu 3
page
–
PRESENT INPUT SIGNAL, HORN

Description: Signal from mini-wheel or steering lever (audible signal).
DIAG STEERING 3(X)
HORN X Connection: signal from S149-2/1 to digital in D790-1/K9:10
STEER.WHEEL CUT OFF X
007624
Signal value:
0 No signal.
PRESENT INPUT SIGNAL, STEER. WHEEL CUT OFF

Description: Signal from sensor steering angle.
Connection: Signal from B770/2 to digital in D790-2/K8:2
Function: 5.2.12 Sensor steering angle
Signal value:
0 No signal.

146 8 Control system – 8.4.11.2 EL-STEERING
EL-STEERING, menu 4
page
–
OUTPUT STEERING LEFT, REFERENCE

Description: Status for control current to control valve for mini-wheel/
DIAG STEERING 4(X) lever steering, solenoid valve steering left.
OUTPUT STEERING LEFT
REQUIRED VALUE XXX Connection: output signal, reference value out from D797-2/K1:3 to
005570
FEEDBACK XXX Y636-4/1
Function: 5.2.10 Control valve, mini-wheel/lever steering
Signal value:
NOTE
OUTPUT STEERING LEFT, REQUIRED VALUE

mini-wheel/lever steering, solenoid valve steering left.
Y636-4/2
OUTPUT STEERING LEFT, FEEDBACK

Description: Present control current to control valve for mini-wheel/le-
ver steering, solenoid valve steering left.
Y636-4/2

EL-STEERING, menu 5
page
–
OUTPUT STEERING RIGHT, REFERENCE

Description: Status for control current to control valve for mini-wheel/
DIAG STEERING 5(X) lever steering, solenoid valve steering right.
OUTPUT STEERING RIGHT
REQUIRED VALUE XXX Connection: output signal, reference value out from D797-2/K1:2 to
005571
FEEDBACK XXX Y636-3/1
Signal value:
NOTE
OUTPUT STEERING RIGHT, REQUIRED VALUE

Description: Reference valve for control current to control valve for
mini-wheel/lever steering, solenoid valve steering right.
Y636-3/2
OUTPUT STEERING RIGHT, FEEDBACK

Description: Present control current to control valve for mini-wheel/le-
ver steering, solenoid valve steering right.
Y636-3/2

148 8 Control system – 8.4.11.3 EXT-ATTACH
8.4.11.3 EXT-ATTACH
EXT-ATTACH, description
page
–
DIAGNOSIS EXTRA
VBFS EL-STEERING This group cover external attachment functions.
EXT-ATTACH FREELIFT
007625
EXT-ATTACH, menu 1
page
–
PRESENT INPUT SIGNAL, EXT-ATTACH ACTIVE

Description: Signal which indicates if external attachment is connect-
DIAG EXT-ATTACH 1(X) ed.
EXT-ATTACH ACTIVE X Connection: -
007626
Function: 7.10.5 Separate top lift attachment

Signal value:
0 No signal.
EXT-ATTACH, menu 2
page
–
PRESENT INPUT SIGNALS, LOCK TW

Description: Signal from switch for locking twistlock.
DIAG EXT-ATTACH 2(X) Circuit diagram: Circuit 7.9-1
LOCK TW X Connection: signal from S1003/2 to digital in D790-1/K8:12
UNLOCK TW X Function: 7.10.5 Separate top lift attachment.
007627
Signal value:
0 No signal.
PRESENT INPUT SIGNALS, UNLOCK TW

Description: Signal from switch/control lever for opening the twistlock.
Function: 7.1.1 Control lever, 7.10.5 Separate top lift attachment
Signal value:
0 No signal.

8 Control system – 8.4.11.3 EXT-ATTACH 149
EXT-ATTACH, menu 3
page
–
PRESENT INPUT SIGNALS, SPREADING OUT

DIAG EXT-ATTACH 3(X) Circuit diagram: Circuits 7.5-1, 7.0-2
SPREADING OUT X Connection: signal from S1012/7 (S815/16) to digital in D790-1/K7:13
SPREADING IN X Function: 7.5 Spreading, 7.1.1 Control lever
007628
Signal value:
0 No signal.
PRESENT INPUT SIGNALS, SPREADING IN

Function: 7.5 Spreading, 7.1.1 Control lever
Signal value:
0 No signal.
EXT-ATTACH, menu 4
page
–
PRESENT INPUT SIGNALS, ALIGNMENT

Description: Signal from alignment sensor.
DIAG EXT-ATTACH 4(X)
ALIGNMENT X Connection: Signal from B7202L/R and B7203L/R to digital in D790-1/
LOCKED TW X K10:3
007629
UNLOCKED TW X
Signal value:
0 No signal.
PRESENT INPUT SIGNALS, LOCKED TW

Description: Signal from sensor for locked twistlocks.
Connection: Signal from B7205L/R to digital in D790-1/K8:8
Signal value:
0 No signal.

150 8 Control system – 8.4.11.3 EXT-ATTACH
PRESENT INPUT SIGNALS, UNLOCKED TW

Description: Signal from sensor for open twistlock.
Connection: Signal from B7204L/R to digital in D790-1/K8:9
Signal value:
0 No signal.
EXT-ATTACH, menu 5
page
–
Not used.
EXT-ATTACH, menu 6
page
–
PRESENT OUTPUT SIGNAL 4TH FUNCTION, TW ACTIVE

Description: Voltage feed to relay for activating twistlock.
DIAG EXT-ATTACH 6(X) Circuit diagram: Circuit 7.0-5
4:E FUNCTION Connection: digital out from D790-1/K7:10 to K3005/86
TW ACTIVE XY Function: 7.10.5 Separate top lift attachment
007631
SPREADING ACTIVE XY
Signal value:


PRESENT OUTPUT SIGNAL 4TH FUNCTION, SPREADING

ACTIVE
Description: Voltage feed to relay for activating spreading.
Connection: digital out from D790-1/K7:11 to K3006/86
Signal value:



8 Control system – 8.4.11.3 EXT-ATTACH 151
EXT-ATTACH, menu 7
page
–
OUTPUT SPREADING IN, REFERENCE

Description: Status for control current to load handling control valve
DIAG EXT-ATTACH 7(X) (solenoid valve, spreading in).
OUTPUT SPREADING IN
REFERENCE Circuit diagram: Circuit 7.5-1
XY
007632
FEEDBACK XXX
Function: 7.5.5 Control valve, load handling
Signal value:
NOTE
OUTPUT SPREADING IN, REQUIRED VALUE

Description: Reference value for control current to load handling con-
trol valve (solenoid valve, spreading in).
Y6019/2
OUTPUT SPREADING IN, FEEDBACK

Description: Present control current to load handling control valve (so-
lenoid valve, spreading in).
Y6019/2

152 8 Control system – 8.4.11.4 FREELIFT
EXT-ATTACH, menu 8
page
–
OUTPUT SPREADING OUT, REFERENCE

Description: Status for control current to load handling control valve
DIAG EXT-ATTACH 8(X) (solenoid valve, spreading out).
OUTPUT SPREADING OUT
REFERENCE Circuit diagram: Circuit 7.5-1
XY
007633
FEEDBACK XXX
Signal value:
NOTE
OUTPUT SPREADING OUT, REQUIRED VALUE

Description: Reference value for control current to load handling con-
trol valve (solenoid valve, spreading out).
Y6018/2.
OUTPUT SPREADING OUT, FEEDBACK

Description: Present control current to load handling control valve (so-
lenoid valve, spreading out).
Y6018/2
8.4.11.4 FREELIFT
FREELIFT, description
page
–
DIAGNOSIS EXTRA
VBFS EL-STEERING This group covers freelift functions.
EXT-ATTACH FREELIFT
008912

8 Control system – 8.4.11.5 MOVE-CAB 153
FREELIFT, menu 1
page
–
PRESENT INPUT SIGNAL MAST CARRIAGE, MAST POS

DOWN
Description: Signal from sensor, mast down.
DIAG FREELIFT 1(X) Circuit diagram: Circuit 7.2-3
MAST CARRIAGE Connection: Signal from B261 to digital in D797-1/K1:11
MAST POS DOWN X Function: 7.2.10 Mast position sensor
007635
LIFT CARRIAGE TOP X
Signal value:
0 No signal.
PRESENT INPUT SIGNAL MAST CARRIAGE, LIFT

CARRIAGE TOP
Description: Signal from sensor, mast up.
Connection: Signal from B260 to digital in D797-1/K1:12
Function: 7.2.10 Mast position sensor
Signal value:
0 No signal.
8.4.11.5 MOVE-CAB
MOVE-CAB, description
page
–
DIAGNOSIS EXTRA
VBFS EL-STEERING This group covers tiltable cap functions.
EXT-ATTACH FREELIFT
008913
MOVE-CAB, menu 1
page
–
INPUT SWITCHES, UP
Description: Signal from switch for manual cab tilt, cab up.
DIAG MOVE-CAB 1(X) Circuit diagram: Circuit 9.10-1
INPUT SWITCHES
UP/RIGHT X Connection: signal from S1010/1 to digital in D790-1/K8:6
DOWN/LEFT X Function: 9.10.4 Cab tilt
007133
OPEN DOORS X
Signal value:
0 No signal.

154 8 Control system – 8.4.11.5 MOVE-CAB
INPUT SWITCHES, DOWN

Description: Signal from switch for manual cab tilt, cab down.
Connection: signal from S1010:/7 to digital in D790-1/K8:7
Function: 9.10.4 Cab tilt
Signal value:
0 No signal.
INPUT SWITCHES, OPEN DOORS

Description: Signal from sensor for opening doors.
Connection: signal from S266-LE/2 to S266-RI/2 to digital in D790-1/
K11:3
Function: 9.10.2 Doors
Signal value:
0 No signal.
MOVE-CAB, menu 2
page
–
PRESENT INPUT SIGNAL, AUTO CAB TILT

Description: Signal from switch for automatic/manual cab tilt.
AUTO CABTILT X Connection: signal from S199-2/1 to digital in D790-1/K8:14
LIFT HEIGHT POS X Function: 9.10.4 Cab tilt
005447
Signal value:
0 No signal.
PRESENT INPUT SIGNAL, LIFT HEIGHT POS

Description: Signal from sensor for automatic cab tilt.
Signal value:
0 No signal.

MOVE-CAB, menu 3
page
–
PRESENT INPUT SIGNAL, CAB UPPER POS

Description: Signal from sensor for cab tilt, cab in upper position.
CAB UPPER POS X Connection: signal from B769-1/C to digital in D797-2/K1:13
CAB LOWER POS X Function: 9.10.4 Cab tilt
005448
Signal value:
0 No signal.
PRESENT INPUT SIGNAL, CAB LOWER POS

Description: Signal from sensor for cab tilt, cab in lower position.
Signal value:
0 No signal.
MOVE-CAB, menu 4
page
–
PRESENT OUTPUT SIGNAL, VALVE CAB UP

Description: Voltage feed to cab tilt control valve, cab up.
DIAG MOVE-CAB 4(X)
VALVE CAB UP XY Connection: digital out from D797-2/K1:29 to Y6047/1
VALVE CAB DOWN XY
005449
Signal value:



156 8 Control system – 8.4.11.5 MOVE-CAB
PRESENT OUTPUT SIGNAL, VALVE CAB DOWN

Description: Voltage feed to cab tilt control valve, cab down.
Signal value:


MOVE-CAB, menu 5
page
–
PRESENT OUTPUT SIGNAL, ACTIVATE SLID-CAB

Description: Voltage feed to control valve to activate sliding cab.
ACTIVATE SLID-CAB XY Connection: digital out from D797-2/K1:25 to Y6080/1
Function: 9.10.4 Hydraulic sliding cab
007134
Signal value:



MOVE-CAB, menu 6
page
–
OUTPUT RIGHT, REFERENCE

DIAG MOVE-CAB 6(X) (solenoid valve, side shift right).
OUTPUT RIGHT
007135
FEEDBACK XXX
Signal value:
NOTE
OUTPUT RIGHT, REQUIRED VALUE

load handling (solenoid valve, side shift right).
Y6021/2
OUTPUT RIGHT, FEEDBACK

lenoid valve, side shift right).
Y6019/2

158 8 Control system – 8.4.11.6 OPT
MOVE-CAB, menu 7
page
–
OUTPUT LEFT, REFERENCE

DIAG MOVE-CAB 6(X) (solenoid valve, side shift left).
OUTPUT LEFT
007136
FEEDBACK XXX
Signal value:
NOTE
OUTPUT LEFT, REQUIRED VALUE

load handling (solenoid valve, side shift left).
Y6020/2
OUTPUT LEFT, FEEDBACK

lenoid valve, side shift left).
Y6020/2
8.4.11.6 OPT
OPT, description
page
–
This group covers a number of options.

DIAGNOSIS EXTRA
VBFS EL-STEERING Confirm selection with function key for Enter.
EXT-ATTACH FREELIFT
008914

8 Control system – 8.4.11.6 OPT 159
OPT, menu 1
page
–
OPTION SWITCH, S199-1

Description: Signal from switch S199-1.
DIAG OPTION 1(X) Circuit diagram: Circuit 9.1-1
OPTION SWITCH
S199-1 X S199-4 X Connection: signal from S199-1/1 to digital in D790-1/K6:9
S199-2 X Function: -
005488
S199-3 X
Signal value:
0 No signal.

Function: -
Signal value:
0 No signal.

Function: -
Signal value:
0 No signal.

Function: -
Signal value:
0 No signal.

OPT, menu 2
page
–
PRESENT OUTPUT SIGNAL CENTRAL LUBRICATION,

FRAME
Description: Voltage feed to central lubrication of frame.
DIAG OPTION 2(X)
CENTRAL LUBRICATION Connection: digital out from D797-1/K1:42 to M693-1/1
FRAME XY
Function: 9.14.1 Pump unit
005489
ATTACHMENT XY
Signal value:


PRESENT OUTPUT SIGNAL CENTRAL LUBRICATION, AT-

TACHMENT
Description: Voltage feed to central lubrication of attachment.
Function: 9.14.1 Pump unit
Signal value:

signal is active.

8 Control system – 8.4.11.6 OPT 161
OPT, menu 3
page
–
PRESENT OUTPUT SIGNAL, D797-1/K1:42

Description: Voltage feed from D797-1/K1:42.
DIAG OPTION 3(X)
Circuit diagram: -
D797-1 C1 P42 XY Connection: digital out D797-1/K1:42
Function: -
005490
Signal value:


OPT, menu 4
page
–

DIAG OPTION 4(X)
Circuit diagram: -
D797-2 C1 P28 XY Connection: digital out from D797-2/K1:28
D797-2 C1 P42 XY
Function: -
005491
Signal value:




Circuit diagram: -
Connection: digital out from D797-2/K1:42
Function: -
Signal value:


OPT, menu 5
page
–

DIAG OPTION 5(X)
Circuit diagram: -
D791-1 C1 P14 XY Connection: digital out from D791-1/K1:14
D791-1 C1 P28 XY
Function: -
005492
Signal value:

signal is active.

Circuit diagram: -
Connection: digital out from D791-1/K1:28
Function: -
Signal value:



8 Control system – 8.4.11.7 RMI 163
8.4.11.7 RMI
RMI, description
page
–
This group covers RMI (Remote Machine Interface) functions.

DIAGNOSIS EXTRA
VBFS EL-STEERING Confirm selection with function key for Enter.
EXT-ATTACH FREELIFT
007657
RMI, menu 1
page
–
MIU SW VER
Description: Software version in RMI interface.
DIAG RMI 1(X) Circuit diagram: -
MIU SW VER XXXX.XXXX
MIU TIME XX.XX.XX Connection: -
Function: 11.6.5 RMI (Remote Machine Interface)
010094
Signal value: xxxx.xxxx = software number.
MIU TIME
Description: Date setting in RMI interface.
Circuit diagram: -
Connection: -
Signal value: xxxx.xx.xx = Date in format YYYY.MM.DD.
RMI, menu 2
page
–
SIGNAL QUALITY, GSM

Description: Signal strength of GSM signal through receiver in the RMI
DIAG RMI 2(X) interface.
SIGNAL QUALITY
GSM XXX GPRS XXX Circuit diagram: Circuit 8.2-4
WLAN XXX RADIO XXX Connection: -
007659
SMS XXX: UNS.DATA XXX

Signal value: XXX = 0-100 = Signal strength, 0-100%.
SIGNAL QUALITY, GPRS

Description: Signal strength of GPRS signal through receiver in the
RMI interface.
Connection: -
SIGNAL QUALITY, WLAN

Description: Signal strength of WLAN signal through receiver in the
RMI interface.

164 8 Control system – 8.4.11.7 RMI

Connection: -
SIGNAL QUALITY, RADIO

Description: Signal strength of RADIO signal through receiver in the
RMI interface.
Connection: -
SIGNAL QUALITY, SMS

Description: Signal strength of SMS signal through receiver in the RMI
interface.
Connection: -
SIGNAL QUALITY, UNS.DATA

Description: Amount of unsent data in line in transmitter part in the RMI
interface.
Connection: -
Signal value: XXX = 0-100 = Data amount in percent of transmitter
buffer, 0-100%.

8 Control system – 8.4.11.7 RMI 165
RMI, menu 3
page
–
ERROR
Description: Internal error code for the RMI interface
DIAG RMI 3(X) Circuit diagram: Circuit 8.2-4
ERROR XX.XX.XX.XX
ERR.VALID XX.XX.XX.XX Connection: -
ACT ERR XX.XX.XX.XX Function: 11.6.5 RMI (Remote Machine Interface)
007660
Signal value: XX.XX.XX.XX = Error code
ERR.VALID
Connection: -
ACT.ERR
Connection: -

166 8 Control system – 8.5 Settings
8.5 Settings
Settings, general
page
–
Settings are built-in functions to adapt the functions to the unique ma-
chine individual. Settings are performed via menus in the display. Set-
tings are divided into initiation and calibration.
Initiation
Initiation, which involves setting start and stop currents for the steering
and hydraulic functions, is performed before the machine is used in
work. This is done to compensate for mechanical and electrical toler-
ances (variations between different machines).
Calibration
Calibration is performed after the machine has started to be used for
work, after change of control units, and in certain cases, service or
change of components. Calibration is performed so that certain func-
tions shall function properly and show correct values.
8.5.1 Initiation
Initiation, description
page
–
1 2
DANGER
INIT ELSERVO 1(X)
START CURRENT The settings influence the functions. Adjustments
LIFT may impair the function. If uncertain, contact Kalmar
4 STORED VALUE XXXmA 3 Industries Service.
008891
PRESENT VALUE XXXmA
Example of initiation menu, start current for lift func- NOTE

tion.
Initiation does not need to be performed in one process but each
1. Menu group step can be performed separately, independently of other steps.
2. Number of menus. Because the number of menus In order that hydraulic functions shall work satisfactorily and safely,
depends on machine configuration, it is specified as certain values must be set to operate the machine, this is known as in-
(X) in this manual. itiation.
3. Signal value
Initiation consists of several menus grouped according to functions.
4. Current variable
Each individual menu sets a specific variable. The menus are similar
in construction and use a common terminology explained here:
PRESENT
Displays the stored value when the menu is opened. Adjust the value
with the plus and minus keys. Save the set value with the Enter key.
Go to the next menu with the arrow keys. Go back with the R-key.
STORED
States the stored value for the current variable.

8 Control system – 8.5.1 Initiation 167
START CURRENT
I [mA]
Specifies the start current to the solenoid valve for the selected func-
1 tion. The start current is the lowest current that can be actuated. In
2 practice, this controls how slowly a function can be operated. On func-
tions with analogue control activation (variable), e.g. lift, this is the cur-
3
006299
rent that is triggered when the lever leaves the zero position. On
t [s] certain functions with digital activation (off/on) which are soft-started,
1. Max. current (END CURRENT) this is the current which is triggered immediately the function is activat-
2. Damping (PROC DAMPING) ed.
3. Start current (START CURRENT)
END CURRENT
Specifies the max. current to the solenoid valve for the selected func-
tion. The max. current is the highest current that can be triggered. In
practice, it controls how quickly a function can be operated. On func-
tions with analogue control activation (controllable), e.g. lift, this is the
current when the lever is in the end position. On certain functions with
digital activation (off/on) which are soft-started, this is the current
which is triggered after the ramp time when the function is activated.
The interval between START CURRENT and END CURRENT is the
active range for controlling the solenoid valve.
PROC DAMPING
Specifies how much the control current shall be reduced during damp-
ing. The interval is specified as 0-100% of the active range between
START CURRENT and END CURRENT.
Overview, initiations DCF360-450CSG
Function Menu
INIT DRIVE-TRAIN, menu 9 page 195
1 Engine, speed limitation (limitation of engine speed

1 Engine, automatic shut-down on idling
1 Engine, automatic engine speed increase for lifting INIT DRIVE-TRAIN, menu 13 page 197
2 Transmission, starting gear INIT DRIVE-TRAIN, menu 1 page 193
2 Transmission, speed limit shifting forward - reverse INIT DRIVE-TRAIN, menu 2 page 193
2 Transmission, engine speed limit shifting forward - reverse INIT DRIVE-TRAIN, menu 3 page 194
2 Transmission, engine speed limit shifting neutral - gear INIT DRIVE-TRAIN, menu 4 page 194
2 Transmission, engine speed limit kickdown to 1st INIT DRIVE-TRAIN, menu 5 page 194
2 Transmission, speed limit declutch INIT DRIVE-TRAIN, menu 6 page 195

2 Transmission, speed limitation (gear lock-out)
2 Transmission, automatic engine speed reduction for shift forward - reverse INIT DRIVE-TRAIN, menu 12 page 196
7.2 Lifting/lowering, lift mast INIT ELSERVO, menu 1 page 173

INIT ELSERVO, menu 2 page 173

168 8 Control system – 8.5.1 Initiation
Function Menu
7.2 Lifting/lowering, lower mast INIT ELSERVO, menu 3 page 174
Note: The current value is for unladen machines. When loaded, the current INIT ELSERVO, menu 4 page 174
value is controlled by the limited lowering speed.
7.3 Extension out INIT ATTACH for DCF360-450CSG page 179

INIT ATTACH, menu 2 page 180
7.3 Extension in INIT ATTACH, menu 3 page 180

7.4 Side shift INIT ATTACH, menu 5 page 181

7.5 Spreading out INIT ATTACH, menu 9 page 182

7.5 Spreading in INIT ATTACH, menu 12 page 183

7.7 Tilt INIT ELSERVO, menu 5 page 174

7.8 Levelling INIT ATTACH, menu 7 page 181


Overview, initiations DCF 280-500
Function Menu
1 Engine, speed limitation (limitation of engine speed)


2 Transmission, automatic engine speed reduction for shift forward - re- INIT DRIVE-TRAIN, menu 12 page 196
verse
5.2 Power assisted system (product option lever steering or mini- INIT STEERING, menu 1 page 188
wheel), lever response
wheel), speed dependent INIT STEERING, menu 3 page 189
INIT STEERING, menu 4 page 190
wheel), steering angle right INIT STEERING, menu 8 page 191
wheel), steering angle left INIT STEERING, menu 10 page 192


Note: The current value is for unladen machines. When loaded, the cur- INIT ELSERVO, menu 4 page 174
rent value is controlled by the limited lowering speed.
7.2 Lifting/lowering, lift carriage INIT ELSERVO, menu 13 page 177

7.2 Lifting/lowering, lower carriage INIT ELSERVO, menu 15 page 178

Note: The current value is for unladen machines. When loaded, the cur- INIT ELSERVO, menu 16 page 178
rent value is controlled by the limited lowering speed.

Function Menu
7.4 Side shift INIT ELSERVO, menu 9 page 176
7.5 Spreading INIT ELSERVO, menu 11 page 176


9.10.4 Hydraulic sliding cab INIT SLID-CAB, menu 1 page 198

INIT SLID-CAB, menu 2 page 199

Overview, initiations DCF 90-100
Function Menu
1 Engine, speed limitation (limitation of engine speed)


2 Transmission, automatic engine speed reduction for shift forward INIT DRIVE-TRAIN, menu 12 page 196
- reverse


Note: The current value is for unladen machines. When loaded, the INIT ELSERVO, menu 4 page 174
current value is controlled by the limited lowering speed.
7.4 Side shift INIT ATTACH, menu 5 page 184

7.5 Spreading out INIT ATTACH, menu 9 page 185

7.5 Spreading in INIT ATTACH, menu 12 page 186


7.8 Levelling INIT ATTACH, menu 7 page 181


Initiate hydraulic function, work instruction

page
–
To select a hydraulic function to initiate, proceed as follows:

All hydraulic functions are initiated the same way.
1 Navigate to the service menu.
2 Press Enter.
000056
3 Enter the code for initiation.
1 23
4 5 NOTE
000060
The code determines which service menu is activated (Diag-

nostic test, Initiation or Calibration).
4 Select group by scrolling with the arrow keys (1 and 2) and con-
INITIATION firm with Enter.
ELSERVO ATTACHMENT
STEERING DRIVE-TRAIN Each initiation consists of a sequence of a number of menus. The
SLIDING-CAB first menu for the selected initiation opens in the display. Select
007169
RETURN the desired menus with the arrow keys (1 and 2).
5 Change the current value with the plus and minus keys.
INIT ELSERVO 1(X)
START CURRENT
LIFT NOTE
STORED VALUE XXXmA Current values can only be adjusted within specific limits.
005494
PRESENT VALUE XXXmA 6 Use the function key for Enter to store the desired current value
setting, "STORED".

8 Control system – 8.5.1.1 ELECTRIC SERVO 173
8.5.1.1 ELECTRIC SERVO

INIT ELSERVO
page
–
The menu group for this function covers initiation of the electric servo
INITIATION functions for load handling.
ELSERVO ATTACHMENT
STEERING DRIVE-TRAIN For DCF360-450CSG and DCF 90-100, settings are made for lift, low-
SLIDING-CAB er, tilt in and tilt out. For other load handling functions, see INIT AT-
007169
RETURN TACH page 179.
For DCF 280-500, settings are made for lift, lower, tilt in, tilt out, side
shift left, side shift right, spreading in and spreading out.
DANGER
The settings affect the functions lift, lower, tilt, and,
for DCF370-500, spreading and side shift. Adjustment
can impair functionality. If in doubt, contact Kalmar
Industries Service.
NOTE
step can be performed separately, independently of other steps.
INIT ELSERVO, menu 1

page
–
START CURRENT, LIFT

INIT ELSERVO 1(X)
Description: Start current for activation of solenoid valve, lift mast
START CURRENT
LIFT (Y6005).
STORED VALUE XXXmA PRESENT VALUE: Indicates the current value for the start current.
005494
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function: 7.2.5 Control valve, lift and tilt (DCF360-450CSG)
7.2.6 Load handling control valve (DCF 280-500)
Component: Solenoid valve, lift mast (Y6005)
Signal value: XXXmA = 0 - 999 mA.

page
–
END CURRENT, LIFT

INIT ELSERVO 2(X)
Description: Control current on full lever actuation for the activation of
END CURRENT
LIFT the solenoid valve for mast lift (Y6005).
STORED VALUE XXXmA PRESENT VALUE: Indicates the current value for max. current. Adjust
005495
PRESENT VALUE XXXmA the value with the plus and minus keys. Save the set value with the En-
ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
STORED VALUE indicates stored value for max. current.

174 8 Control system – 8.5.1.1 ELECTRIC SERVO


page
–
START CURRENT, LOWER

INIT ELSERVO 3(X)
Description: Start current for the activation of the solenoid valve for
START CURRENT
LOWER mast lowering (Y6004).
005496
with the R-key.
Component: Solenoid valve, lower mast(Y6004)

page
–
END CURRENT, LOWER

INIT ELSERVO 4(X)
END CURRENT
LOWER the solenoid valve for mast lowering (Y6004).
005497
R-key.
Component: Solenoid valve, stand (Y6004)

page
–
START CURRENT, TILT IN

INIT ELSERVO 5(X)
Description: Start current for the activation of the solenoid valve for tilt
START CURRENT
TILT IN in (Y6011).
007139
with the R-key.
Component: Solenoid valve, tilt in (Y6011)


page
–
END CURRENT, TILT IN

INIT ELSERVO 6(X)
END CURRENT
TILT IN the solenoid valve for tilt in (Y6011).
007140
R-key.
Component: Solenoid valve, tilt in (Y6011)

page
–
START CURRENT, TILT OUT

INIT ELSERVO 7(X)
Description: Start current for the activation of the solenoid valve for tilt
START CURRENT
TILT OUT out (Y6010).
007141
with the R-key.
Component: Solenoid valve, tilt out (Y6010)

page
–
END CURRENT, TILT OUT

INIT ELSERVO 8(X)
END CURRENT
TILT OUT the solenoid valve for tilt out (Y6010).
007142
R-key.
Component: Solenoid valve, tilt out (Y6010)


page
–
START CURRENT, SIDE SHIFT LE/RI

INIT ELSERVO 9(X)
Description: Start current of activation of solenoid valve for side shift
START CURRENT
SIDESHIFT LE/RI left (Y6020) and solenoid valve for side shift right (Y6021).
007143
with the R-key.
Function: 7.4.5 Load handling control valve (DCF 280-500)
Component: Solenoid valve for side shift left (Y6020) and solenoid
valve for side shift right (Y6021)

page
–
END CURRENT, SIDE SHIFT LE/RI

INIT ELSERVO 10(X)
Description: Control current at full lever actuation for activation of so-
END CURRENT
SIDESHIFT LE/RI lenoid valve for side shift left (Y6020) and solenoid valve for side shift
STORED VALUE XXXmA right (Y6021).
007144
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for max. current. Adjust
the value with the plus and minus keys. Save the set value with the En-
R-key.
Function: 7.4.5 Load handling control valve (DCF 280-500)
valve for side shift right (Y6021)

page
–
START CURRENT, SPREADING IN/OUT

INIT ELSERVO 11(X)
Description: Start current for activation of solenoid valve for spreading
START CURRENT
SPREADING IN/OUT in (Y6019) and solenoid valve for spreading out (Y6018).
007145
with the R-key.
Component: Solenoid valve for spreading in (Y6019) and solenoid
valve for spreading out (Y6018)


page
–
END CURRENT, SPREADING IN/OUT

INIT ELSERVO 12(X)
END CURRENT
SPREADING IN/OUT lenoid valve for spreading in (Y6019) and solenoid valve for spreading
STORED VALUE XXXmA out (Y6018).
007146
R-key.
Component: Solenoid valve for spreading in (Y6019) and solenoid
valve for spreading out (Y6018)

page
–
START CURRENT, LIFT 2

INIT ELSERVO 13(X)
Description: Start current for activation of solenoid valve, lift carriage
START CURRENT
LIFT 2 (Y6022).
007147
with the R-key.
Function 7.2.6 Solenoid valve, load handling
Component: Solenoid valve, lift carriage (Y6022)

page
–
END CURRENT, LIFT 2

INIT ELSERVO 14(X)
END CURRENT
LIFT 2 the solenoid valve for carriage lift (Y6022).
007148
R-key.
Component: Solenoid valve, lift carriage (Y6022)


page
–
START CURRENT, LOWER 2

INIT ELSERVO 15(X)
Description: Start current for activation of solenoid valve, lower car-
START CURRENT
LOWER 2 riage (Y6023).
007149
with the R-key.
Component: Solenoid valve, lower carriage (Y6023)

page
–
END CURRENT, LOWER 2

INIT ELSERVO 16(X)
END CURRENT
LOWER 2 the solenoid valve for carriage lowering (Y6023).
007150
R-key.
Component: Solenoid valve, lower carriage (Y6023)

page
–
DAMP (PROC), LIFT

INIT ELSERVO 17(X)
Description: Percentage damping of control current to solenoid valve
DAMP (PROC)
LIFT for mast lift (Y6005) when the mast reaches max height.
STORED VALUE XX PRESENT VALUE: Indicates the current value for damping. Adjust the
PRESENT VALUE XX value with the plus and minus keys. Save the set value with the Enter
I [mA] key. Go to the next menu with the arrow keys. Exit initiation with the R-
key.
1
STORED VALUE: indicates stored value in percent.
2 Function: 7.2.5 Control valve, lift and tilt (DCF360-450CSG)
3
007151

t [s]
1. Max. current (END CURRENT)
2. Damping (PROC DAMPING) Signal value: XXX = 0 - 100%. 100% means no damping i.e. max. cur-
3. Start current (START CURRENT) rent. 0% means full damping i.e. start current

8 Control system – 8.5.1.2 ATTACHMENT 179
8.5.1.2 ATTACHMENT
INIT ATTACH
page
–
This function initiates the attachment functions extension, side shift,

INITIATION spreading, rotation and controllable levelling for DCF360-450CSG
ELSERVO ATTACHMENT (see INIT ATTACH for DCF360-450CSG page 179) and side shift,
STEERING DRIVE-TRAIN
spreading and controllable levelling for DCF 90-100 (see INIT AT-
SLIDING-CAB
TACH for DCF 90-100 page 184).
007170
RETURN
DANGER
The settings affect the functions extension, side shift,
spreading, rotation and controllable levelling for
DCF360-450CSG and the functions side shift, spread-
ing and controllable levelling for DCF 90-100. Adjust-
ments could impair functionality. In the event of
uncertainty, contact Kalmar Industries Service.
NOTE
INIT ATTACH for DCF360-450CSG

page
–
INIT ATTACH, menu 1

START CURRENT, PROJECTION OUT
INIT ATTACH 1(X)
Description: Start current for activation of solenoid valve for extension
START CURRENT
PROJECTION OUT left side out (Y6046-2) and solenoid valve for extension right side out
STORED VALUE XXXmA (Y6046-4).
005509
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for the start current.
Adjust the value with the plus and minus keys. Save the set value with
with the R-key.
Component: Solenoid valve, extend left side out (Y6046-2), Solenoid
valve, extend right side out (Y6046-4).
Signal value: XXXmA = 0 - 999 mA

180 8 Control system – 8.5.1.2 ATTACHMENT
INIT ATTACH, menu 2

END CURRENT, PROJECTION OUT
INIT ATTACH 2(X)
END CURRENT
PROJECTION OUT left side out (Y6046-2) and solenoid valve for extension right side out
005510
R-key.
INIT ATTACH, menu 3

START CURRENT, PROJECTION IN
INIT ATTACH 3(X)
START CURRENT
PROJECTION IN left side in (Y6046-1) and solenoid valve for extension right side in
005511
Adjust the value with the plus and minus keys. Save the set value with
with the R-key.
INIT ATTACH, menu 4

END CURRENT, PROJECTION IN
INIT ATTACH 4(X)
Description: Control current at full lever angle for activation of solenoid
END CURRENT
PROJECTION IN valve for extension left side in (Y6046-1) and solenoid valve for exten-
STORED VALUE XXXmA sion right side in (Y6046-3).
005512
R-key.

INIT ATTACH, menu 5

START CURRENT, SIDE SHIFT
INIT ATTACH 5(X)
START CURRENT
SIDESHIFT left (Y6020) and solenoid valve for side shift right (Y6021).
005513
with the R-key.
valve for side shift right (Y6021).
INIT ATTACH, menu 6

END CURRENT, SIDE SHIFT
INIT ATTACH 6(X)
END CURRENT
SIDESHIFT lenoid valve for side shift left (Y6020) and solenoid valve for side shift
005514
R-key.
INIT ATTACH, menu 7

Not used.
INIT ATTACH, menu 8

Not used.

INIT ATTACH, menu 9

START CURRENT, SPREADER OUT, 20’-40’
INIT ATTACH 9(X)
START CURRENT
SPREADER OUT, 20'-40' out 20’-40’ (Y6018).
I [mA] the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
1
2 Function: 7.5.2 Control valve attachment
3 005517
Component: Solenoid valve for spreading out 20’-40’ (Y6018)
t [s]
2. Damping (PROC DAMPING)
INIT ATTACH, menu 10

END CURRENT, SPREADER OUT, 20’-40’
INIT ATTACH 10(X)
END CURRENT
SPREADER OUT, 20'-40' lenoid valve for spreading out 20’-40’ (Y6018).
I [mA] ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
1
3
005518

t [s]

DAMP (PROC), SPREADER OUT, 20’-40’
INIT ATTACH 11(X)
DAMP (PROC)
SPREADER OUT, 20'-40' for spreading in 20’-40’ (Y6018) when outward spreader approaches
STORED VALUE XX 40’.
PRESENT VALUE XX PRESENT VALUE: Indicates the current value for damping. Adjust the
I [mA] value with the plus and minus keys. Save the set value with the Enter
key. Go to the next menu with the arrow keys. Exit initiation with the R-
1 key.
2 STORED VALUE: indicates stored value in percent.
005519
t [s] Component: Solenoid valve for spreading out 20’-40’ (Y6018)

1. Max. current (END CURRENT) Signal value: XXX = 0 - 100%. 100% means no damping i.e. max. cur-
2. Damping (PROC DAMPING) rent. 0% means full damping i.e. start current


START CURRENT, SPREADER IN, 40’-20’
INIT ATTACH 12(X)
START CURRENT
SPREADER IN, 40'-20' in 40’-20’ (Y6019).
with the R-key.
1
3
005520
Component: Solenoid valve for spreading in 40’-20’ (Y6019)
t [s]

END CURRENT, SPREADER IN, 40’-20’
INIT ATTACH 13(X)
END CURRENT
SPREADER IN, 40'-20' lenoid valve for spreading in 40’-20’ (Y6019).
I [mA] ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
1
3
005521
Component: Solenoid valve for spreading in 40’-20’ (Y6019)

t [s]

DAMP (PROC), SPREADER IN, 40’-20’
INIT ATTACH 14(X)
DAMP (PROC)
SPREADER IN, 40'-20' for spreading in 40’-20’ (Y6019) when inward spreader approaches
STORED VALUE XX 20’
1 key.
005522
t [s] Component: Solenoid valve for spreading in 40’-20’ (Y6019)

1. Max. current (END CURRENT) Signal value: XXX = 0 - 100%. 100% means no damping i.e. max. cur-
2. Damping (PROC DAMPING) rent. 0% means full damping i.e. start current

INIT ATTACH for DCF 90-100

page
–
INIT ATTACH, menu 1

Not used.
INIT ATTACH, menu 2

Not used.
INIT ATTACH, menu 3

Not used.
INIT ATTACH, menu 4

Not used.
INIT ATTACH, menu 5

START CURRENT, SIDE SHIFT
INIT ATTACH 5(X)
START CURRENT
SIDESHIFT left (Y6020) and solenoid valve for side shift right (Y6021).
005513
with the R-key.
INIT ATTACH, menu 6

END CURRENT, SIDE SHIFT
INIT ATTACH 6(X)
END CURRENT
SIDESHIFT lenoid valve for side shift left (Y6020) and solenoid valve for side shift
005514
R-key.

INIT ATTACH, menu 7

START CURRENT, LEVELLING
INIT ATTACH 7(X)
Description: Start current of activation of solenoid valve for levelling
START CURRENT
LEVELLING left (Y6036) and solenoid valve for levelling right (Y6035).
010067
with the R-key.
Component: Solenoid valve for levelling left (Y6036), solenoid valve
for levelling right (Y6035).
INIT ATTACH, menu 8

END CURRENT, LEVELLING
INIT ATTACH 7(X)
END CURRENT
LEVELLING lenoid valve for levelling left (Y6036) and solenoid valve for levelling
010068
R-key.
Component: Solenoid valve for levelling left (Y6036), solenoid valve
for levelling right (Y6035).
INIT ATTACH, menu 9

START CURRENT, SPREADER OUT, 20’-40’
INIT ATTACH 9(X)
START CURRENT
SPREADER OUT, 20'-40' out left (Y6018L) and solenoid valve for spreading out right (Y6018R)
with the R-key.
1
3
005517

t [s]


END CURRENT, SPREADER OUT, 20’-40’
INIT ATTACH 10(X)
END CURRENT
SPREADER OUT, 20'-40' lenoid valve for spreading out left (Y6018L) and solenoid valve for
STORED VALUE XXXmA spreading out right (Y6018R).
I [mA] the value with the plus and minus keys. Save the set value with the En-
1 R-key.
2 STORED VALUE indicates stored value for max. current.
3 005518
t [s] Component: Solenoid valve for spreading out left (Y6018L) and sole-
1. Max. current (END CURRENT) noid valve for spreading out right (Y6018R).
2. Damping (PROC DAMPING) Signal value: XXXmA = 0 - 999 mA

DAMP (PROC), SPREADER OUT, 20’-40’
INIT ATTACH 11(X)
DAMP (PROC)
SPREADER OUT, 20'-40' for spreading out left (Y6018L) and solenoid valve for spreading out
STORED VALUE XX right (Y6018R) when spreading out approaches 40’.
1 key.
005519
t [s] Component: Solenoid valve for spreading out left (Y6018L) and sole-
1. Max. current (END CURRENT) noid valve for spreading out right (Y6018R).

START CURRENT, SPREADER IN, 40’-20’
INIT ATTACH 12(X)
START CURRENT
SPREADER IN, 40'-20' in left (Y6019L) and solenoid valve for spreading in right (Y6019R)
with the R-key.
1
3
005520
Component: Solenoid valve for spreading in left (Y6019L) and sole-

t [s] noid valve for spreading in right (Y6019R).
1. Max. current (END CURRENT) Signal value: XXXmA = 0 - 999 mA


END CURRENT, SPREADER IN, 40’-20’
INIT ATTACH 13(X)
END CURRENT
SPREADER IN, 40'-20' lenoid valve for spreading in left (Y6019L) and solenoid valve for
STORED VALUE XXXmA spreading in right (Y6019R)
1 R-key.
t [s] 005521 Component: Solenoid valve for spreading in left (Y6019L) and sole-
1. Max. current (END CURRENT) noid valve for spreading in right (Y6019R).
2. Damping (PROC DAMPING) Signal value: XXXmA = 0 - 999 mA

DAMP (PROC), SPREADER IN, 40’-20’
INIT ATTACH 14(X)
DAMP (PROC)
SPREADER IN, 40'-20' for spreading in left (Y6019L) and solenoid valve for spreading in right
STORED VALUE XX (Y6019R) when spreading in approaches 20’.
1 key.
005522
t [s] Component: Solenoid valve for spreading in left (Y6019L) and sole-
1. Max. current (END CURRENT) noid valve for spreading in right (Y6019R).

188 8 Control system – 8.5.1.3 STEERING
8.5.1.3 STEERING
INIT STEERING
page
–
This function covers initiation of lever steering or mini-wheel.

INITIATION
ELSERVO ATTACHMENT
SLIDING-CAB DANGER
007171
RETURN
The settings affect the function of lever steering or
mini-wheel. Adjustments can impair functionality.
Contact Kalmar Industries Service in the event of un-
certainty.
NOTE
INIT STEERING, menu 1

page
–
CHARACTER OF THE STEERING LEVER

INIT STEERING 1(X)
Description: Indicates the responsiveness of the steering lever in ac-
CHARACTER OF THE
STEERING LEVER, 0-31 cordance with 32 predefined curves (0-31) 0 means that linear wheel
STORED VALUE XX angle is uniform in relation to lever angle during the whole lever move-
PRESENT VALUE XX ment. 31 means that the wheel angle is small at the beginning of the
lever movement and large at the end.
U [V] 0
PRESENT VALUE: indicates current curve. Change curve with the
plus or minus keys. Save the set curve with the Enter key. Go to the
next menu with the arrow keys. Go back from initiation using the R key.
31
STORED VALUE: indicates saved curve.
Function: 5.2 Power assisted system (product option lever steering or
005572
mini-wheel)
X Component: -
U = Output signal to solenoid valve
Signal value: XX = 0-31.
X = Lever movement

8 Control system – 8.5.1.3 STEERING 189

page
–
BREAK POINT BP1

INIT STEERING 2(X)
Description: Speed for cut-off point 1. Cut-off points are used to adapt
BRAKE POINT BP1
(kph) the steering angle to the machine’s speed. This enables both sensitive
STORED VALUE XX.X steering at low speeds and stable steering at higher speeds.
PRESENT VALUE XX.X PRESENT VALUE: indicates present speed setting for cut-off point 1.
I [mA] Change speed with plus or minus keys. Save set speed with the Enter-
100% key. Go to the next menu with arrow keys. Exit initiation with the R-key.
STORED VALUE: indicates saved speed for break point 1.
% BP2 Function: 5.2 Power assisted system (product option lever steering or
% BP3 mini-wheel)
005573
V [kph] Component: -
BP1 BP2 BP3
I [mA] = control current to solenoid valve Signal value: XX.X = speed for BP1 in km/h.
V [kph] = machine’s speed in km/h
BP1 = speed setting for break point 1
%BP2 = per cent of control current to solenoid valve at
BP2
BP3

page
–
BREAK POINT BP2

INIT STEERING 3(X)
Description: Speed for cut-off point 2. Cut-off points are used to adapt
BRAKE POINT BP2
(kph) the steering angle to the machine’s speed. This enables both sensitive
STORED VALUE XX.X steering at low speeds and stable steering at higher speeds.
PRESENT VALUE XX.X PRESENT VALUE: indicates present speed setting for cut-off point 2.
I [mA] Change speed with plus or minus keys. Save set speed with the Enter-
100% key. Go to the next menu with arrow keys. Exit initiation with the R-key.
STORED VALUE: indicates saved speed for break point 2.
% BP3 mini-wheel)
005574
V [kph] Component: -
BP1 BP2 BP3
I [mA] = control current to solenoid valve Signal value: XX.X = speed for BP2 in km/h.
V [kph] = machine’s speed in km/h
BP2
BP3


page
–
BREAK POINT BP3

INIT STEERING 4(X)
Description: Speed for cut-off point 3. The cut-off points are used to
BRAKE POINT BP3
(kph) adapt the steering angle in accordance with the machine’s speed. This
STORED VALUE XX.X enables both sensitive steering at low speeds and stable steering at
PRESENT VALUE XX.X higher speeds.
I [mA] PRESENT VALUE: indicates present speed setting for cut-off point 1.
100% Change speed with plus or minus keys. Save set speed with the Enter-
key. Go to the next menu with arrow keys. Exit initiation with the R-key.
% BP2 STORED VALUE: indicates saved speed for break point 3.
V [kph] 005575 mini-wheel)
BP1 BP2 BP3
Component: -
I [mA] = control current to solenoid valve
V [kph] = machine’s speed in km/h Signal value: XX.X = speed for BP3 in km/h.
BP2
BP3

page
–
PROC REDUCTION, AT PB2

INIT STEERING 5(X)
Description: Percentage reduction of control current to solenoid valve
PROC REDUCTION
AT BP2 for steering right (Y636-3) and solenoid valve for steering left (Y636-4)
STORED VALUE XXX at BP2.
PRESENT VALUE XXX PRESENT VALUE: Indicates the current value for the reduction. Ad-
I [mA] just the value with the plus and minus keys. Save the set value with
100% the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
% BP2 STORED VALUE: indicates stored value for the reduction.
005576
V [kph] mini-wheel)
BP1 BP2 BP3
Component: -
V [kph] = machine’s speed in km/h Signal value: XXX = 0 - 100%. 100% means no damping, i.e.. max.
BP1 = speed setting for break point 1 current. 0% means full damping, i.e., start current.
BP2
BP3

8 Control system – 8.5.1.3 STEERING 191

page
–
PROC REDUCTION, AT PB3

INIT STEERING 6(X)
Description: Percentage reduction of control current to solenoid valve
PROC REDUCTION
AT BP3 for steering right (Y636-3) and solenoid valve for steering left (Y636-4)
STORED VALUE XXX at BP3.
PRESENT VALUE XXX PRESENT VALUE: Indicates the current value for the reduction. Ad-
I [mA] just the value with the plus and minus keys. Save the set value with
100% the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
% BP2 STORED VALUE: indicates stored value for the reduction.
005577
V [kph] mini-wheel)
BP1 BP2 BP3
Component: -
V [kph] = machine’s speed in km/h Signal value: XXX = 0 - 100%. 100% means no damping, i.e.. max.
BP1 = speed setting for break point 1 current. 0% means full damping, i.e., start current.
BP2
BP3

page
–
START CURRENT, STEERING RIGHT

INIT STEERING 7(X)
Description: Start current to the solenoid valve for steering right (Y636-
START CURRENT
STEERING RIGHT 3).
005578
with the R key.
Function: 5.2.10 Control valve, lever steering/mini wheel
Component: Solenoid valve for steering right (Y636-3)

page
–
END CURRENT, STEERING RIGHT

INIT STEERING 8(X)
Description: Control current to the solenoid valve for steering right
END CURRENT
STEERING RIGHT (Y636-3) at end lever position.
005579
R key.
Component: Solenoid valve for steering right (Y636-3)


page
–
START CURRENT, STEERING LEFT

INIT STEERING 9(X)
Description: Start current to the solenoid valve for steering left (Y636-
START CURRENT
STEERING LEFT 4).
005580
with the R-key.
Component: Solenoid valve for steering left (Y636-4)

page
–
END CURRENT, STEERING LEFT

INIT STEERING 10(X)
Description: Control current to the solenoid valve for steering left
END CURRENT
STEERING LEFT (Y636-4) at end lever position.
005581
R-key.
Component: Solenoid valve for steering left (Y636-4)

8 Control system – 8.5.1.4 DRIVETRAIN 193
8.5.1.4 DRIVETRAIN
INIT DRIVE-TRAIN
page
–
This function covers engine and transmission initiation.

INITIATION
ELSERVO ATTACHMENT
SLIDING-CAB DANGER
007172
RETURN
The settings affect engine and transmission function.
Adjustments can impair the functionality. Contact Ka-
lmar Industries Service in the event of uncertainty.
NOTE
The machine must be stationary with applied parking brake to en-
able access to the menus.
After changes have been made, the ignition must be turned off
and on for the changes to be saved and start to apply.
INIT DRIVE-TRAIN, menu 1

page
–
START IN 2ND
INIT DRIVE-TRN 1(X)
Description: Setting to get transmission to start in 2nd gear instead of
START IN 2:ND
1=YES 0=NO in 1st. Kick-down to 1st takes place as needed.
STORED VALUE XXX PRESENT VALUE: Indicates the current setting. Change the value
005525
PRESENT VALUE XXX with the plus and minus keys. Save the set value with the Enter key.
Go to the next menu with the arrow keys. Exit initiation with the R-key.
STORED VALUE: indicates saved setting.
Component: -
Signal value: XXX = 1= yes, XXX = 0 = no

page
–
VEHICLE SPEED F-R

INIT DRIVE-TRN 2(X)
Description: Setting of highest permitted speed for shifting between
VEHICLE SPEED F-R
forward and reverse.
005582
Component: -
Signal value: XXX = speed in km/h

194 8 Control system – 8.5.1.4 DRIVETRAIN

page
–
ENGINE SPEED F-R

INIT DRIVE-TRN 3(X)
Description: Setting of highest permitted engine speed when shifting
ENGINE SPEED F-R
between forward and reverse.
STORED VALUE XXX
005583
PRESENT VALUE XXX NOTE
If the rpm is set lower than the engine’s idle rpm, shifting will not
be allowed.
PRESENT VALUE: Indicates the current setting. Change the value
Component: -
Signal value: XXX = engine speed (rpm)

page
–
ENGINE SPEED N-DIR

INIT DRIVE-TRN 4(X)
Description: Setting of highest permitted engine speed for shifting from
ENGINE SPEED N-DIR
neutral to gear.
STORED VALUE XXX
005584

This setting takes priority over the setting in INIT DRIVE-TRAIN,
menu 3 page 194. If the engine speed is set lower in this menu
that in menu 3, this engine speed will also apply to switching di-
rection of travel. This occurs because the transmission must shift
into neutral when changing direction of travel.
Component: -

page
–
ENGINE SPEED, KICKDOWN 1ST

INIT DRIVE-TRN 5(X)
Description: Setting of the lowest engine rpm when conditions for kick-
ENGINE SPEED
KICK DOWN 1:ST down to 1st gear are to be checked.
STORED VALUE XXX
007152

If the rpm is set too low, kick-down may take place before the ma-
chine has used the engagement on the selected gear.
If the rpm is set too high, kick-down takes place slowly or not at
all.


Component: -

page
–
VEHICLE SPEED, DECLUTCH

INIT DRIVE-TRN 6(X)
Description: Setting of highest permitted speed for disengaging the
VEHICLE SPEED
DECLUTCH transmission.
005586
Component: -
Signal value: XXX = speed (km/h)

page
–
Not used.

page
–
Not used.

page
–
OPTION SPEED LIMIT

INIT DRIVE-T 9(X)
OPTION SPEED LIMIT
(km/h)
Description: Setting of speed limitation.
STORED VALUE XXX
005587
PRESENT VALUE XXX PRESENT VALUE: Indicates the current setting. Change the value
Component: -
Signal value: XXX = speed (km/h)

page
–
OPTION HIGHEST GEAR AT SPEED LIMIT

INIT DRIVE-T 10(X)
OPTION HIGHEST GEAR
AT SPEED LIMIT
Description: Setting of highest permissible gear (speed limitation
STORED VALUE XXX
005588
PRESENT VALUE XXX through blocked gears).


196 8 Control system – 8.5.1.4 DRIVETRAIN

Component: -
Signal value: XXX = gear

page
–
OPTION ENGINE SHUT DOWN

INIT DRIVE-T 11(X)
OPTION ENGINE SHUT
DOWN AT IDLE (sec)
Description: Setting of idle time prior to automatic engine shutdown
STORED VALUE XXX 005589
PRESENT VALUE XXX PRESENT VALUE: Indicates the current setting. Change the value
Function: 1 Engine
Component: -
Signal value: XXX = time in seconds before engine shutdown.

page
–
F-R WITHOUT ENGINE SPEED REDUCTION

INIT DRIVE-T 12(X)
Description: Activation or deactivation of automatic engine speed re-
F-R WITHOUT ENGINE
SPEED REDUCTION duction when changing direction of travel forward - reverse. This
STORED VALUE X makes it possible to change direction of travel without releasing the ac-
005590
PRESENT VALUE X celerator pedal. Engine speed drops to that set in menu 3 (see INIT
DRIVE-TRAIN, menu 3 page 194). If no value is set in menu 3, engine
speed goes to idle speed.
Component: -
Signal value:
X = 1, activated
X = 0, deactivated


page
–
AUTO ENGINE SPEED AT LIFT

INIT DRIVE-T 13(X)
AUTO ENGINE SPEED AT
LIFT
Description: Activation or deactivation of automatic engine speed in-
STORED VALUE X
005591
PRESENT VALUE X crease during lift.
Component: -
Signal value:
X = 1, activated
X = 0, deactivated

198 8 Control system – 8.5.1.5 SLIDING-CAB
8.5.1.5 SLIDING-CAB
INIT SLIDING-CAB
page
–
This function handles initiation of the hydraulic sliding cab.

INITIATION
ELSERVO ATTACHMENT The sliding cab is smooth started by means of the control current to
STEERING DRIVE-TRAIN the solenoid valves being increased from a low start value to a max.
SLIDING-CAB level. When the cab reaches an end position the speed is dampened
007161
RETURN by means of the control current being reduced.
DANGER
The settings affect the function of the hydraulic slid-
ing cab. Adjustments can impair functionality. Con-
tact Kalmar Industries Service in the event of
uncertainty.
NOTE
INIT SLID-CAB, menu 1

page
–
START CURRENT, RIGHT

INIT SLID-CAB 1(X)
Description: Start current to solenoid valve side shift right (Y6021) at
START CURRENT
RIGHT activation of sliding cab. The control current controls the start speed
STORED VALUE XXXmA for cab sliding to the right.
I [mA] Adjust the value with the plus and minus keys. Save the set value with
1 with the R-key.
2 STORED VALUE: indicates stored value for start current.
3 Function: 9.10.4 Hydraulic sliding cab
007162
t [s] Component: Solenoid valve, side shift right (Y6021)


8 Control system – 8.5.1.5 SLIDING-CAB 199

page
–
END CURRENT, RIGHT

INIT SLID-CAB 2(X)
Description: Control current to solenoid valve for side shift right
END CURRENT
RIGHT (Y6021) after full ramp time at activation of switch for cab sliding. This
STORED VALUE XXXmA current controls maximum speed cab sliding speed to the right.
1 R-key.
t [s] 007163 Component: Solenoid valve, side shift right (Y6021)

page
–
Not used.

page
–
START CURRENT, LEFT

INIT SLID-CAB 4(X)
Description: Start current to solenoid valve side shift left (Y6020) at ac-
START CURRENT
LEFT tivation of sliding cab. The control current controls the start speed for
STORED VALUE XXXmA cab sliding to the left.
I [mA] Adjust the value with the plus and minus keys. Save the set value with
1 with the R-key.
2 STORED VALUE: indicates stored value for start current.
007165
t [s] Component: Solenoid valve, side shift left (Y6020)


200 8 Control system – 8.5.1.5 SLIDING-CAB

page
–
END CURRENT, LEFT

INIT SLID-CAB 5(X)
Description: Control current to solenoid valve for side shift left (Y6020)
END CURRENT
LEFT after full ramp time at activation of switch for cab sliding. This current
STORED VALUE XXXmA controls maximum speed cab sliding speed to the left.
1 R-key.
3 007166 Function: 9.10.4 Hydraulic sliding cab
t [s] Component: Solenoid valve, side shift left (Y6020)

page
–
Not used.

8 Control system – 8.5.2 Calibration 201
8.5.2 Calibration
Calibration, description
page
–
Certain functions require calibration in order to operate correctly. The

control system has integrated calibrations for these functions.
SCALE
This menu handles calibration of sensors to weight indication.
CALIBRATION
Dynamic scale, calibration page 203
SCALE STEERING
DRIVE-TRAIN RETURN
000062
STEERING
This menu handles calibration of the steering lever for lever steering,
CALIBRATION see:
SCALE STEERING Lever steering, calibration page 203

DRIVE-TRAIN RETURN
000074
NOTE
Calibration does not need to be performed in one process but
each step can be performed separately, independently of other
steps.
DRIVETRAIN
This function handles calibrations for engine and transmission. The
CALIBRATION menu loop contains two different calibrations which are not connected
to each other, see:
SCALE STEERING
DRIVE-TRAIN RETURN Accelerator pedal, calibration page 204
000078
Transmission, calibration page 206
NOTE
steps.

202 8 Control system – 8.5.2 Calibration
Calibration menu, explanation

The figure shows an example of a menu, here for calibrating the centre
1 2
position of the lever steering control. The table indicates what a de-
scription contains (which follows in the next section):
5 CALIBR STEERING 1(X)
STEERING LEVER CENTER
POSITION Designation: Example Description
4 STORED VALUE X.XXV
3 Variable (position 5): STEERING LE- Name of the affected input sig-
008892
PRESENT VALUE X.XXV
VER CENTRE POSITION nal/control signal.
1. Menu group Description: Setting the centre posi- A short description of what is
2. Sequence number. Because the number of menus tion of the lever steering control calibrated and the meaning of
depends on machine configuration, it is specified as (R825). the variables.
(X) in this manual.
STORED VALUE: Gives the stored
3. Signal value
signal value for lever steering control
4. STORED indicates stored value, PRESENT indi-
(R825), centre position.
cates current value of the signal to be calibrated
5. Heading of menu figure PRESENT VALUE: Gives the
present signal value for lever steer-
ing control (R825), centre position.
Function: 5.2 Power assisted system Name of current function.
Component: Lever steering control Indicates the component

(R825) whose signal is the basis for
calibration.
Calibration, work instructions

page
–
Calibration consists of a number of menus (the number of menus de-

pends on the function). All menus are similar in construction and there-
fore the descriptions are similar.
To select a function to calibrate, proceed as follows:
1 Navigate to the service menu.

2 Press Enter.
000056
3 State code for calibration.

1 23
4 5 NOTE
000060
The code determines which service menu is activated (Diag-

nostic test, Initiation or Calibration).
4 Select group by scrolling with the arrow keys (1 and 2) and con-
CALIBRATION firm with Enter.
SCALE STEERING Each calibration consists of a sequence of a number of menus.

DRIVE-TRAIN RETURN The first menu for the selected calibration appears in the display.
000062
Select the next menu with key 1 and 2 (arrow function).

8 Control system – 8.5.2.1 Calibrate SCALE 203
8.5.2.1 Calibrate SCALE

Dynamic scale, calibration
page
–
1 Park the machine on level ground with the mast vertical and with-
out load.
CALIBR SCALE, menu 1

2 Go into the calibration menus and select CALIBR SCALE, menu
CALIBR SCALE 1(X) 1, see Calibration, work instructions page 202
PRESENT LOAD XXXXXkg
Description: Setting of dead weight (tare).
STORED TARE XXXXXkg PRESENT LOAD: indicates present load.
PRESENT TARE XXXXXkg 007154
PRESENT TARE: indicates present dead weight (tare).
STORED VALUE: indicates stored dead weight (tare).
3 Move the mast to the position where weighing normally is done.
Lower just a little and wait until the value in present load has sta-
bilised.
4 Store values with function key for Enter.
CALIBR SCALE, menu 2
CALIBR SCALE 2(X)
Description: Diagnostic menu for scale. The values come from the Ve-
PRESENT LOAD XXXXXkg
LIFT PRESSURE XXXbar hicle data file and cannot be adjusted.
GEAR RATIO MAST X PRESENT LOAD: indicates present load.
007155
CYL. AREA XXXXXmm2

LIFT PRESSURE: indicates lift pressure.
GEAR RATIO MAST: indicates gear ratio for the mast.
CYL. AREA: indicates cylinder area.
8.5.2.2 Calibrate STEERING

Lever steering, calibration
page
–
NOTE
steps.
1 Start key in operating position.
CALIBR STEERING, menu 1

2 Go into the calibration menus and select CALIBR STEERING,
CALIBR STEERING 1(X) menu 1, see Calibration, work instructions page 202
STEERING LEVER CENTER
POSITION STEERING LEVER CENTRE POSITION
STORED VALUE X.XXV Description: Setting the centre position of the lever steering con-
005529
PRESENT VALUE X.XXV trol (R825).

PRESENT VALUE: indicates current signal value from lever
steering control (R825).
STORED VALUE: indicates stored signal value from lever steer-
ing control (R825).

204 8 Control system – 8.5.2.3 Calibrate DRIVETRAIN
Component: Lever steering control (R825)

3 Move steering lever to required centre position.
4 Store the position with function key for Enter.

5 Select CALIBR STEERING, menu 2.
CALIBR STEERING 2(X)
STEERING LEVER LEFT POSITION
STEERING LEVER LEFT
POSITION Description: Setting of position for max. angle left on lever steer-
STORED VALUE X.XXV 005530 ing control (R825).
PRESENT VALUE X.XXV
PRESENT VALUE: indicates current signal value from lever
steering control (R825).
ing control (R825).
6 Move steering lever to required position for max. angle left.

8 STEERING LEVER RIGHT POSITION
CALIBR STEERING 3(X)
Description: Setting of position for max. angle right on lever steer-
STEERING LEVER RIGHT
POSITION ing control (R825).
STORED VALUE X.XXV PRESENT VALUE: indicates current signal value from lever
005531
PRESENT VALUE X.XXV steering control (R825).

ing control (R825).
9 Move steering lever to required position for max. angle right.
8.5.2.3 Calibrate DRIVETRAIN

Accelerator pedal, calibration
page
–
To calibrate the accelerator pedal for forward driving, use steps 1-7.
To calibrate accelerator pedal 2 (if there is a reversible operator’s
seat), use step 1 + 8-13.
1 Start key in operating position, engine switched off.

8 Control system – 8.5.2.3 Calibrate DRIVETRAIN 205
DRIVE-TRAIN, menu 1
2 Go into the calibration menus and select DRIVE-TRAIN, menu 1,
CALIBR DRIVE-TRN 1(X) see Calibration, work instructions page 202.
ACCELERATOR,
RELEASE THE PEDAL ACCELERATOR, RELEASE THE PEDAL
STORED VALUE X.XXV Description: setting accelerator’s pedal zero position.
005532
PRESENT VALUE X.XXV
STORED VALUE: Indicates current calibrated control value from
accelerator pedal (R690-1).
PRESENT VALUE: Indicates present signal value from Acceler-
ator pedal (B690-1).
Function: 1 Engine
Component: Accelerator pedal (B690-1).
3 Release the accelerator pedal.
DRIVE-TRAIN, menu 2
5 ACCELERATOR, PRESS THE PEDAL TO FLOOR
CALIBR DRIVE-TRN 2(X) Description: Setting of full-throttle position of Accelerator pedal
ACCELERATOR, PRESS (B690-1).
THE PEDAL TO FLOOR
STORED VALUE X.XXV STORED VALUE: Indicates current calibrated control value from
PRESENT VALUE X.XXV accelerator pedal (R690-1).
00

Function: 1 Engine
6 Press the accelerator pedal down fully and keep it down until the
position is stored.
DRIVE-TRAIN, menu 5
8
CALIBR DRIVE-TRN 5(X)
ACCELERATOR 2, Go into the calibration menus and select DRIVE-TRAIN, menu 5;
RELEASE THE PEDAL see Calibration, work instructions page 202.
STORED VALUE X.XXV
ACCELERATOR 2, RELEASE THE PEDAL
005534
PRESENT VALUE X.XXV

Description: Calibration of accelerator pedal 2, for driving rear-
ward on machines with reversible operator’s seat. Setting of ac-
celerator pedal’s zero position.
Function: 1 Engine
9 Release the accelerator pedal.

DRIVE-TRAIN, menu 6
11
CALIBR DRIVE-TRN 6(X)
ACCELERATOR 2, PRESS ACCELERATOR 2, PRESS THE PEDAL TO FLOOR
THE PEDAL TO FLOOR Description: Calibration of accelerator pedal 2 for driving rear-
STORED VALUE X.XXV
ward on machines with a reversible operator’s seat. Setting of full
005535
PRESENT VALUE X.XXV
throttle position for the accelerator pedal (B690-2).
Function: 1 Engine
12 Press the accelerator pedal down fully and keep it down until the
position is stored.
Transmission, calibration
page
–
DANGER
Do not leave the machine during calibration. The ma-
chine may start to move.
1 Park the machine on level ground, engage neutral position and

apply the parking brake. Run the engine at idling speed.
2 Go into the calibration menus and select DRIVE-TRAIN, menu 4,
CALIBR DRIVE-TRN 4(X) see Calibration, work instructions page 202.
GEARBOX WARM UP
MODE X 3 Check that the oil temperature is at least 61 °C.
ACTUAL TEMP XXX If the oil temperature is too low then go to DRIVE-TRAIN, menu 4.
005610
TARGET TEMP XXX

A. Apply the service brake so that the machine is stationary.
B. Select travel direction forward and apply full throttle for 20
seconds.
C. Engage neutral position, apply full throttle for 10 seconds
and then run the engine at idling speed.
D. Repeat steps B and C until the oil is hot.
The engine speed may be reduced towards the end of heating as
the oil from the gearbox is too hot. If this occurs, maintain neutral
position and maintain an engine speed of 1200 rpm for 20 sec-
onds.
When the temperature is correct, MODE changes from 0 to 1.

8 Control system – 8.5.2.3 Calibrate DRIVETRAIN 207
4 Select DRIVE-TRAIN, menu 3.

CALIBR DRIVE-TRN 3(X) GEARBOX TUNING
START AUTO CALIBR
PHASE X SUB-PH X Description: Calibration of transmission couplings.
CLUTCH X STATUS X
005609
ACTION X XXXXrpm PHASE: Indicates current phase in the calibration.
0. Pre-filling of clutch
1. Calibration of clutch
4. Calibration complete
5. Calibration incorrect
CLUTCH: Indicates which clutch shall be calibrated.

F. Clutch forward
R. Clutch reverse
1. Clutch gear 1
2. Clutch gear 2
3. Clutch gear 3
4. Clutch gear 4
ACTION: Indicates action from mechanics (in the event of a

fault)
0. No action (normal condition if no malfunction).
1. Increase throttle application.
2. Reduce throttle application.
3. Select neutral position.
4. Select travel direction forward.
5. Stop the vehicle (depress the service brake if the
machine starts to move).
6. Heat the transmission, see step 4.
7. No action; the engine is controlled via the transmis-
sion control unit (D793).
8. Keep the accelerator pedal in its current position.
9. Check error codes.
SUB-PH: Internal value for sub-phase 1 or 0.
STATUS: Calibration status.

0. Calibration not in progress.
3. Calibration in progress.
5 Check that the gear selector is in neutral position.

6 Start calibration by pressing Enter.
7 Calibration starts (takes approx. 15 minutes) and engine speed is
raised to approx. 770 rpm.
The transmission will activate different gears during calibration.

NOTE
If the machine starts to move during calibration, use the
service brake to keep the machine stationary.
IMPORTANT
Calibration can be interrupted at any time by selecting
travel direction reverse.
8 When the engine speed decreases to idling and PHASE = 4 then

calibration is complete.
9 Switch off the ignition to store the values.

9 Frame, body, cab and accessories 1
Table of Contents 9 Frame, body, cab and accessories

mm mm mm mm mm mm
9 Frame, body, cab and accessories............................................................... 5

9.1.1 Gear selector and multi-function lever ................................................. 12
9.1.22 Switch, direction indicators .................................................................. 14
9.2 Safety and emergency equipment ............................................................ 15
9.2.1 Emergency stop switch ........................................................................ 15
9.2.2 Seat belt ............................................................................................... 15
9.2.3 Fire extinguisher .................................................................................. 15
9.2.4 Seat buzzer .......................................................................................... 15
9.2.5 Roof grating ......................................................................................... 15
9.3 Seat .......................................................................................................... 16
9.3.1 Seat cushion ........................................................................................ 20
9.3.2 Back cushion ....................................................................................... 20
9.3.3 Electric heater ...................................................................................... 21
9.3.4 Shock absorbers .................................................................................. 22
9.3.5 Air suspension ..................................................................................... 22
9.3.6 Compressed air-suspended seat ......................................................... 22
9.3.7 Mechanical seat adjustment ................................................................ 23
9.3.8 Passenger seat .................................................................................... 23
9.3.9 Reversible operator's seat ................................................................... 23
9.3.10 Rotating operator’s seat ....................................................................... 27
9.3.11 Armrest ................................................................................................ 27
9.3.12 Directional valve, reversible operator’s seat ........................................ 28
9.3.13 Reversible operator’s seat sensor ....................................................... 28
9.3.14 Sensor operator in seat ....................................................................... 28
9.4 Heating, ventilation and air conditioning ................................................... 29
9.4.1 Fresh air filter ....................................................................................... 37
9.4.2 Fresh air and recirculation damper ...................................................... 38
9.4.3 Cab fan ................................................................................................ 41
9.4.4 Heat exchanger heat ........................................................................... 44
9.4.5 Water valve .......................................................................................... 47
9.4.6 Engine temperature sensor ................................................................. 48
9.4.7 Compressor ......................................................................................... 48
9.4.8 Condenser ........................................................................................... 51
9.4.9 Moisture filter ....................................................................................... 53
9.4.10 Pressure switch ................................................................................... 53
9.4.11 Expansion valve ................................................................................... 54
9.4.12 Sensor temperature refrigerant ............................................................ 56
9.4.13 Heat exchanger cooling ....................................................................... 58
9.4.14 Air distributor ........................................................................................ 59
9.4.15 Air vents ............................................................................................... 60
9.4.16 Sensor temperature outlet fan ............................................................. 61
9.4.17 Sensor cab temperature ...................................................................... 62
9.4.18 Sensor outdoor temperature ................................................................ 63

2 9 Frame, body, cab and accessories
9.4.19 Pause heater ........................................................................................ 64

9.5 Wiper/washer system ................................................................................ 65
9.5.1 Wiper front ............................................................................................ 65
9.5.2 Wiper roof ............................................................................................. 65
9.5.3 Wiper rear ............................................................................................. 65
9.5.4 Washer motor and reservoir ................................................................. 65
9.5.5 Wiper motor, front ................................................................................. 66
9.5.6 Wiper motor, roof .................................................................................. 67
9.5.7 Wiper motor, rear ................................................................................. 68
9.6 Lighting system ......................................................................................... 70
9.6.1 Headlights ............................................................................................ 75
9.6.2 Running light ........................................................................................ 75
9.6.3 Tail light ................................................................................................ 75
9.6.4 Brake light ............................................................................................ 75
9.6.5 Reversing light ...................................................................................... 76
9.6.6 Driving direction indicator ..................................................................... 76
9.6.7 Flashing hazard lights .......................................................................... 76
9.6.8 Rotating beacon ................................................................................... 76
9.6.9 Working lights, mast ............................................................................. 77
9.6.10 Working lights, cab ............................................................................... 77
9.6.11 Interior lighting ...................................................................................... 78
9.7 Signalling system ...................................................................................... 79
9.7.1 Horn ...................................................................................................... 82
9.7.2 Flashing hazard lights .......................................................................... 83
9.7.3 Rotating beacon ................................................................................... 83
9.7.4 Warning parking brake ......................................................................... 83
9.7.5 Reversing alarm ................................................................................... 83
9.8 Entertainment and communication ........................................................... 84
9.9 Glass/windows/mirrors .............................................................................. 85
9.9.1 Windscreen .......................................................................................... 86
9.9.2 Side window ......................................................................................... 88
9.9.3 Roof window ......................................................................................... 92
9.9.4 Rear window ......................................................................................... 92
9.9.5 Rearview mirror .................................................................................... 93
9.9.6 Reversing camera ................................................................................ 94
9.9.7 Monitor, reversing camera .................................................................... 94
9.10 Cab structure and suspension .................................................................. 95
9.10.1 Cab frame ............................................................................................. 95
9.10.2 Doors .................................................................................................... 96
9.10.3 Cab undercarriage ................................................................................ 96
9.10.4 Hydraulic sliding cab ............................................................................ 97
9.10.5 Cab tipping ......................................................................................... 101
9.11 Cab interior ............................................................................................. 102
9.11.1 Instrument and control panels ............................................................ 102
9.11.2 Interior details, plastic ......................................................................... 103
9.11.3 Interior details, textile ......................................................................... 103
9.11.4 Floor covering ..................................................................................... 104

9 Frame, body, cab and accessories 3
9.11.5 Insulation ........................................................................................... 104

9.11.6 Sun blinds .......................................................................................... 104
9.11.7 Terminal console ............................................................................... 104
9.11.8 Reading-lamp .................................................................................... 104
9.11.9 Writing desk ....................................................................................... 105
9.12 Frame ..................................................................................................... 106
9.13 Body ....................................................................................................... 107
9.13.1 Fenders .............................................................................................. 107
9.13.2 Hood engine compartment ................................................................ 108
9.13.3 Footstep and rail ................................................................................ 108
9.13.4 Counterweights .................................................................................. 108
9.14 Central lubrication .................................................................................. 109
9.14.1 Pump unit ........................................................................................... 111
9.14.2 Distribution block ............................................................................... 112
9.14.3 Lines .................................................................................................. 112
9.15 Paint/coatings ......................................................................................... 113

4 9 Frame, body, cab and accessories

9 Frame, body, cab and accessories – 9 Frame, body, cab and accessories 5
9 Frame, body, cab and

mm mm mm mm mm mm
accessories
Controls and instruments, overview
page
–
Overview
1 2 3 4 5
15
12 13 12 11 10 9 6 8 7
009698
14
1 Left-hand instrument panel

2 Gear and multi-function lever (S162)
3 Steering wheel panel
4 Steering wheel
5 Switch direction indicators (S161)
6 Panel for load handling functions
7 Switch control switch (S250)
8 Switch for parking brake (S107)
9 Hydraulic control
10 Operator’s seat
11 Accelerator pedal (B690)
12 Brake pedals
13 Declutch pedal (S220-1)
14 Fuse box with fuses and relays
15 Hour meter (P708)

6 9 Frame, body, cab and accessories – 9.1 Controls and instruments
A Steering lever or mini-wheel

Left-hand instrument panel
16 Switch fan (S118)
17 Switch, heating (S117)
18 Switch air distribution (S139)
24..28 29 30 31 19 Switch work lights cab roof (S105-1)
19..23
Auxiliary work lights, front wing
18 20 Spare
004394
17
16 21 Switch, work lights on mast (S105-3)
Left-hand instrument panel

Auxiliary work lights, mast
22 Switch rotating beacon (S110)
23 Switch hazard lights (S109)
24 Switch headlights (S100)
25 Switch, seat heater (S143)

(May be found in operator’s seat)
26 Switch, rearview mirror defroster (S199-4)

27 Spare
28 Switch, pause heater (S199-1)

29 Spare
30 Spare
31 Socket 12 VDC

9 Frame, body, cab and accessories – 9.1 Controls and instruments 7
Steering wheel panel

32 Warning lamp, low battery charge
36
35 33 Warning lamp, low brake pressure
34
33 34 Indicator, active error codes
32
35 Warning lamp, bypass of hydraulic functions
36 Indicator lamp, activated joystick or mini-wheel steering

37 Warning lamp, high coolant temperature
37..41 49
38 Warning lamp, low engine oil pressure
42..46 39 Indicator lamp, preheating
47 48 40 Warning lamp, low engine coolant level
41 Warning lamp, high transmission fluid temperature
42 Warning lamp, low fuel level
50 51 52 53 43 Warning lamp, high hydraulic oil temperature
44 Indicator lamp, high beam
45 Indicator lamp, direction indicator
46 Indicator lamp, parking brake
47 Indicator lamp, locked twistlocks (secured load)
48 Indicator lamp, alignment (attachment / load)
49 Indicator lamp, unlocked twistlocks (load released)
64
54 50 Panel, warning and indicator lamps
63 51 Display, control system
55
62 52 Indicator, control system
56
000399
61 60 59 58 57 53 Ignition switch (S150)

54 Switch, defroster
Steering wheel panel for warning and indicator lamps
55 Switch, windscreen wiper at roof, interval
56 Switch, windscreen wiper at roof, continuous
57 Switch interior lighting
58 Switch, rear window wiper, interval
59 Switch, rear window wiper, continuous
60 Function keys, control system
61 Travel direction indicator, Forward Neutral Reverse
62 Switch, shifting program A, automatic shifting
63 Switch, shifting program 1, locked to first gear
64 Switch, shifting program 2, locked to second gear

Panel for load handling functions

65 Lift/lower
69 65
66
67 66 Tilt
68
67 Side shift
68 Fork spreading
69 Not used
70 Switch, horn (S149)
71 Switch for twistlocks, automatic/manual locking (S1003)

70 72 Switch, spreading 20’-40’ (S1012) (attachment)
73 Not used
74 Not used
71
72 75 Not used
73
74 76 Switch, reversible operator’s seat (S169)
75
Switch, hydraulic sliding cab (S1010)
76
77 77 Not used
009700
7 78 8 78
Panel for hydraulic functions and control levers
hydraulic servo
78 Switch, bypass (S1005)
65
66
67 Key for bypass
68
69
70
71
72
73
74
75
76
77
009701
8 78 7 78
Panel for hydraulic functions and control levers
electric servo

75
71
73
76
78
77
009702
78 7 79 70
Panel for hydraulic functions and control lever

Operating menus, overview
1 2 3a 3b
10 5
9 8 7 6
007120
11 12 13
1. Operating menu engine and transmission 7.

Operating menu statistics
2. 8. Operating menu service

Operating menu, scale
3a. Operating menu, engine - for Volvo TAD760VE, Cum- 9. Operating menu, code lock
mins QSB7 and QSM11.
3b. Operating menu, engine - for Volvo TAD952VE and 10. Operating menu heating and air conditioning
TAD1250VE.
4. Operating menu for oil temperature 11.

Operating menu statistics, operating hours
5. Operating menu electrical system 12.

Operating menu statistics, fuel consumption
6. 13
Operating menu service interval Operating menu statistics, driving distance

Event menus overview
1 2
009703
1. Event menu start interlock
2. Event menu open door

12 9 Frame, body, cab and accessories – 9.1.1 Gear selector and multi-function lever
Switch, replacement
–
NOTE
The instructions apply to switches in general.

2 Remove the dashboard panel.
3 Detach the connector from the switch.

4 Remove the switch from the instrument panel. Use a screwdriver
to bend in the tabs.
5 Replace the switch.
9.1.1 Gear selector and multi-function

lever
Gear and multi-function lever, description
page
–
The following functions are handled by the gear and multi-function le-
2 ver (position 2).
3 1
0 Movement Function
Forward/ Travel direction (for selecting shifting program and
Reverse travel direction, see section 2 Transmission).
Inward, Washing of windshield, roof window and rear win-
000338
handle dow.
The signal can be checked from the diagnostic
menu, see section 8 Control system, group 8.4.3.1
CAB, menu 1.

9 Frame, body, cab and accessories – 9.1.1 Gear selector and multi-function lever 13
Movement Function
Rotation Windshield wiper front.
0 – No wiping front windshield. If wiper rear or roof
are active, these run at slow interval wiping.
1 – Slow interval wiping windscreen, controls slow
interval wiping for roof window and rear window.
2 – Fast interval wiping front windshield, controls
fast interval wiping for roof window and rear win-
dow.
3 – Continuous wiping front windshield. If wiper rear
or roof are active, these run at fast interval wiping.
The signal can be checked from the diagnostic
menu, see section 8 Control system, group 8.4.3.2
CAB, menu 2.
Upward Light signal

Down- High beams (on/off)
ward With headlights on: Gear and multi-function lever is
used to switch between high and low beams.
With headlights off: Gear and multi-function lever is
000339
A used to flash with the headlights.

The signal can be checked with the diagnostic menu,
see section 8 Control system, group 8.4.2.3 LIGHTS,
menu 3.
Inward, Horn (position A).
button The signal can be checked from the diagnostic menu,
see section 8 Control system, group 8.4.3.5 CAB,
menu 5.

14 9 Frame, body, cab and accessories – 9.1.22 Switch, direction indicators
Gear and multi-function lever, replacement

page
–
1 Separate the dashboard panel.

6 attaching bolts and 2 bolts to the steering wheel shaft.
Remove the steering wheel, see Dashboard panel, replacement
page 101.
2 Undo the attaching bolts (2 x hexagonal socket bolts).
3 Unplug the connector from the KIT control unit (D790-2).
4 Fit a new lever and refit the dashboard panel.
9.1.22 Switch, direction indicators

Switch, direction indicators, replacement
page
–

2 Remove the steering wheel and open the steering wheel panel.
3 Detach the direction indicator wiring harness.

4 Press together the clips on the direction indicator and detach it
from the steering wheel panel.
5 Replace the direction indicator, fitting it in the reverse order.

9 Frame, body, cab and accessories – 9.2 Safety and emergency equipment 15
9.2 Safety and emergency

equipment
9.2.1 Emergency stop switch
Emergency stop, description
page
–
See section 11 Common electrics, group 11.5.1.4 Emergency stop

switch voltage.
9.2.2 Seat belt

Seat belt, description
page
–
The seat belt is a two or a three-point belt, depending on the type of

seat fitted in the machine. The seat belt is mounted on the seat.
9.2.3 Fire extinguisher

Fire extinguisher, description
page
–
The fire extinguisher is located at the entry on the left frame beam. Us-
age instructions are found on the fire extinguisher.
9.2.4 Seat buzzer

Seat buzzer, description
page
–
See Sensor operator in seat, description page 28.
9.2.5 Roof grating

Roof grating, description
page
–
The roof grating protects the operator from falling objects. This consti-
tutes protection that goes beyond the legal requirements.

16 9 Frame, body, cab and accessories – 9.3 Seat
9.3 Seat
Seat, general
page
–
There are three versions of operator’s seat:

• Seat, description (product alternative standard seat) page 16
• Seat, description (product alternative Bege 9120) page 17
• Seat, description (product alternative Isringhausen 6800)

page 18
As an option, the machine can be equipped with a fold-down passen-

ger seat to the left of the operator.
Seat, description (product alternative standard

page
–
seat)
The seat’s function is to give the operator a good sitting position and
contribute to a good work environment. The cab’s seat has several ad-
justment possibilities and meets high comfort standards.
1 2 The seat has the following equipment:
• mechanical adjustment
3
• right armrest
• left armrest
4
• seat heating
• seat belt
• head restraint
5
• seat heating
8 6
006825
7
Controls, standard seat
1. Lumber support adjustment
2. Right armrest adjustment
3. Left armrest adjustment
4. Backrest rake adjustment
5. Springing position adjustment
6. Seat cushion angle adjustment
7. Seat cushion height adjustment
8. Front/rear adjustment

9 Frame, body, cab and accessories – 9.3 Seat 17
Seat, description (product alternative Bege 9120)

page
–
Bege 9120 is the same as the standard seat, but is equipped with air
1 2 suspension. Air suspension automatically adjusts seat height and
springing to the operator’s weight. Air suspension is supplied by a spe-
cial compressor installed on the underside of the cab.
3
4
The seat has the following equipment:
• mechanical adjustment
• air suspension (with external compressor)
5 • right armrest
• seat belt (3-point)
8 6 • seat heating
006826
7
Controls, Bege 9120 • left armrest
• seat heating
2. Right armrest adjustment
3. Left armrest adjustment • head restraint
4. Backrest rake adjustment
5. Springing position adjustment
6. Seat cushion angle adjustment
7. Seat cushion height adjustment

18 9 Frame, body, cab and accessories – 9.3 Seat
Seat, description (product alternative

page
–
Isringhausen 6800)
The Isringhausen 6800 seat has the following equipment:
• head restraint
• armrest
• air suspension (with external compressor)
• air-adjusted lumbar support
• seat belt (3-point)
• seat heating
11
10
34 567
004691
9 8 2
Controls, Isringhausen 6800
2. Seat cushion adjustment
3. Lowering seat cushion height
4. Seat cushion angle
5. Raising seat cushion height
6. Backrest rake
7. Damping adjustment
8. Seat heating
9. Plane damping off/on
11. Armrest

9 Frame, body, cab and accessories – 9.3 Seat 19
Seat, changing
page
–

2 Slide back the seat to its rear position, remove the front attaching
bolts.
3 Slide the seat to its front position, remove the rear attaching bolts.
4 Disconnect the seat’s connectors from the machine’s cabling.
5 Remove the seat.

20 9 Frame, body, cab and accessories – 9.3.1 Seat cushion
9.3.1 Seat cushion

Seat cushion, description
page
–
The function of the seat cushion is to provide comfort to the operator.

The seat cushion houses the operator’s seat frame and a breaker for
the buzzer. There may also be a heating coil ( ).
For location, see Seat, general page 16.
Seat cushion, changing (product alternative BE-GE)

page
–

2 Loosen the rubber bellows by removing the plastic clips (position
1).
3 Unhook the upholstery’s rails (position 2) from the seat frame (po-
2 5 sition 3) and remove the upholstery.
4 Remove the padding (position 4).
4
If the seat is equipped with seat heater.
Unplug the connector for the heating coil before the padding is re-
moved.
NOTE
The seat’s heating coil is glued to the padding. Be careful if
3
the padding is to be replaced but the heating coil is to be re-
used, or if only the coil is to be replaced.
5 Assemble in reverse order.
1
006276
1. Plastic clips rubber bellows

2. Upholstery
3. Seat frame
4. Padding
5. Heating coil
9.3.2 Back cushion

Back cushion, description
page
–
The function of the back cushion is to provide comfort to the operator.

The back cushion houses the operator’s seat frame. There may also
be a heating coil ( ).

9 Frame, body, cab and accessories – 9.3.3 Electric heater 21
Back cushion, changing (product alternative BE-GE)

page
–
1 Machine in service position, see section B Safety

2 Detach the rubber bellows on the rear of the seat by removing the
plastic clips and folding down the rubber bellows. See Seat cush-
ion, changing (product alternative BE-GE) page 20.
3
3 Remove the backrest by first removing the attaching bolts
(position1) on the right and left side of the seat and then remove
4 the attaching bolts for the seatbelt (position 2) on the right and left
side of the seat.
4 If the seat is equipped with 3-point seatbelt.

Remove the belt guide (position 3) by removing the cover and the
attaching bolt (position 4).
5 5 If the seat is equipped with armrest (position 5).

Remove the armrest by removing the attaching bolts (position 6).
6 Place the backrest on the seat and install the attaching bolts (po-
sition 1), do not tighten. Then install the attaching bolts for the
6 seatbelt (position 2).
Tighten the attaching bolts for the seatbelt (position 2) with torque
42 Nm, then tighten the attaching bolts (position 1) with torque
33 Nm.
7 If the seat is equipped with 3-point seatbelt or armrest.

Cut holes in the upholstery for seatbelt and armrest on the new
006278
1 2 backrest before armrest or seatbelt is installed.
1. Attaching bolt backrest 8 Fit in the reverse order.

2. Attaching bolt seatbelt
3. Cover belt guide
4. Attaching bolt belt guide
5. Armrest
6. Attaching bolt armrest.
9.3.3 Electric heater

Electric heater, description
page
–
The heating coil’s function is to warm the back and seat cushions in
the operator’s seat. The heating coil is located under the upholstery on
the seat.
The heating coil (E803) is supplied power upon warm-up of the cab
control unit (D790-1) via the seat heating relay (K383). The signal can
be checked with the diagnostic menu, see section 8 Control system,
group 8.4.3.8 CAB, menu 8.
Heating coil, changing (product alternative BE-GE)

page
–
See Seat cushion, changing (product alternative BE-GE) page 20.

22 9 Frame, body, cab and accessories – 9.3.4 Shock absorbers
9.3.4 Shock absorbers

Shock absorbers, description
page
–
Shock absorbers are integrated in the suspension unit in the seat’s

bracket and are self-adjusting, that is, they adjust themselves accord-
ing to the operator’s body weight.
Shock absorber, changing (product alternative BE-

page
–
GE)
2 1 Machine in service position, see section B Safety.

2 Remove the operator’s seat from the bracket and lift it out of the
machine. See Seat, changing page 19.
3 Remove the seat cushion; see Seat cushion, changing (product
alternative BE-GE) page 20.
1 4 Remove the back cushion; see Back cushion, changing (product
alternative BE-GE) page 21.
5 Remove the shock absorber’s attaching bolts (position 2 and 3).
6 Replace shock absorber (position 1).
006277
3 7 Assemble in reverse order.

1. Shock absorbers
2. Attaching bolt
3. Attaching bolt
9.3.5 Air suspension

Air suspension, description
page
–
The air-suspended operator’s seat consists of a seat with rubber bel-

lows and compressor. Air suspension is self-adjusting, that is, adjust
automatically to the operator’s body weight. The compressor provides
air for the suspension unit.
9.3.6 Compressed air-suspended seat

Compressed air-suspended seat, description
page
–
Bege 9120:
The compressor is part of the air-suspended operator’s seat and is lo-

cated inside the seat’s suspension unit.
001621
Isringhausen 6800:
Compressed air-suspended seat
The compressor is an external part for the air-suspended operator’s

seat that is installed on the cab floor’s underside.

9 Frame, body, cab and accessories – 9.3.7 Mechanical seat adjustment 23
9.3.7 Mechanical seat adjustment

Mechanical seat adjustment, description
page
–
Seat adjustment is all mechanical and is adapted by the operator with

different controls to obtain a good sitting position.
See:
• Seat, description (product alternative standard seat) page 16
• Seat, description (product alternative Bege 9120) page 17
• Seat, description (product alternative Isringhausen 6800) page 18
9.3.8 Passenger seat

Passenger seat, description
page
–
The passenger seat is collapsible (vertically), provided with a seat belt

and is located on the left-hand side of the operator’s seat.
001627
Passenger seat with bracket
9.3.9 Reversible operator's seat

Reversible operator’s seat, description
page
–
The operator’s station, with seat, is electrically reversible. The electric

motor’s gear changes the position of the operator’s station via a
sprocket.
The seat console has an integrated steering wheel column and steer-
ing wheel with panel. This follows with the console when the seat is re-
versed. The seat itself does not differ from the others.
The reversible operator’s station has doubled pedals. Because the
steering wheel and hand controls follow when the station is reversed,
the directions are changed, e.g. the steering valve and headlights, with
special conversion valves (directional valves). This way, the front part
of the machine always faces the way the operator’s seat faces.
The steering column operates the steering valve via a chain. The chain
has a tensioner which can be adjusted via a hatch in the console.
006144

24 9 Frame, body, cab and accessories – 9.3.9 Reversible operator's seat

Speed Below 2 km/h (at engagement) Section 2 Transmission
Emergency stop Not activated Section 11 Common electrics, group 11.5.1.4 Emergency
switch stop switch voltage
1 13 13
<˚ <˚
D1 D13 D13
2
D790-1
D3
D797-2
3, 5, 9, 11
D8
D5
D9
4, 12 6, 10
A798 8 8
M 7
009705
1 The reversible operator’s seat switch U = 24 V Section 9 Frame, body, cab and accessories,
(S169) sends a voltage signal to the cab group 9.1 Controls and instruments
control unit (D790-1). Reversing of the op- D1: Diagnostic menu, see section 8 Control sys-
erator’s seat stops if the switch is released tem, group 8.4.11.1 VBFS, menu 1
before the seat has reached its end posi-
tion.
2 The cab control unit (D790-1) transmits Checked by control sys- Section 11 Common electrics, group 11.5.3.1
clockwise rotation or anticlockwise rota- tem; error indicated with Cab control unit (D790-1)
tion on the CAN bus. error code.
3 The frame control unit (D797-2) activates U = 24 V Section 11 Common electrics, group 11.5.3.3
the seat reversal brake solenoid valve Frame control unit (D797-2)
(Y676) for release of seat reversal. D3: Diagnostic menu, see section 8 Control sys-
tem, group 8.4.11.1 VBFS, menu 9
4 The seat reversal brake solenoid valve - Control unit, reversible operator’s seat, descrip-
(Y676) releases the brake holding the tion page 26
seat in the locked position.
5 The frame control unit (D797-2) sends a U = 24 V Section 11 Common electrics, group 11.5.3.3
voltage signal to the reversible operator’s Frame control unit (D797-2)
seat control unit (A798) for rotation clock- D5: Diagnostic menu, see section 8 Control sys-
wise or rotation anticlockwise. tem, group 8.4.11.1 VBFS, menu 2

9 Frame, body, cab and accessories – 9.3.9 Reversible operator's seat 25

6 The reversible operator’s seat control unit - Control unit, reversible operator’s seat, descrip-
(A798) supplies voltage to the seat revers- tion page 26
al motor (M675).
7 The seat reversal motor (M675) rotates - Control unit, reversible operator’s seat, descrip-
the operator’s seat. tion page 26
8 The reversible operator’s seat forward U = 24 V Reversible operator’s seat sensor, description
sensor (S720-F) or reversible operator’s page 28
seat rearward sensor (S720-R) sends a D8: Diagnostic menu, see section 8 Control sys-
voltage signal to the frame control unit tem, group 8.4.11.1 VBFS, menu 3
(D797-2) when the seat is in an end posi-
tion, i.e. the seat is facing forward or rear-
ward.
9 The frame control unit (D797-2) sends a U = 24 V Section 11 Common electrics, group 11.5.3.3
voltage signal to the reversible operator’s Frame control unit (D797-2)
seat control unit (A798) to reduce reversal D9: Diagnostic menu, see section 8 Control sys-
speed. tem, group 8.4.11.1 VBFS, menu 9
10 The reversible operator’s seat control unit - Control unit, reversible operator’s seat, descrip-
(A798) reduces the speed of the seat re- tion page 26
versal motor (M675).
11 The frame control unit (D797-2) activates U = 24 V Section 11 Common electrics, group 11.5.3.3
the seat reversal brake solenoid valve Frame control unit (D797-2)
(Y676) for locking of seat reversal. D3: Diagnostic menu, see section 8 Control sys-
12 The seat reversal brake solenoid valve - Control unit, reversible operator’s seat, descrip-
(Y676) activates the brake that prevents tion page 26
the operator’s seat from rotating.
13 The CAN message "operator’s seat facing -

forward" or "operator’s seat facing rear-
ward" control the following:
- Sensors S720-F and S720-R regulate so - Section 5 Steering, group 5.2 Power assisted
that steering deflection is adapted to system
which way the operator’s seat is facing. D8: Diagnostic menu, see section 8 Control sys-
- Accelerator pedal front (B690-1) is inac- - Section 1 Engine

tivated and accelerator pedal rear (B690- D13: Diagnostic menu, see section 8 Control
2) is activated when the operator’s seat system, group 8.4.6.1 ENGINE, menu 1
faces rearward. Accelerator pedal front
(B690-1) is activated and accelerator ped-
system, group 8.4.11.1 VBFS, menu 4
al rear (B690-2) is inactivated when the
operator’s seat faces forward.
- Headlights and rear lights change func- - Signalling system, function description page 79
tion upon reversal of the operator’s seat,
i.e. headlights serve as rear lights and
rear lights serve as headlights. See Light-
ing system, function description page 70.

26 9 Frame, body, cab and accessories – 9.3.9 Reversible operator's seat
Control unit, reversible operator’s seat, description

page
–
The control unit of the reversible operator’s seat (A798) is located on

1 the right side of the rear cab wall. The control unit regulates the revers-
ible operator’s seat function.
009716
1. Control unit, reversible operator’s seat (A798)
Reversible operator’s seat, electric motor,

page
–
description
The electric motor for seat reversal (M675), which rotates the reversi-
ble operator’s seat, is located beneath the cab floor in the seat’s pivot
point. The motor’s gear changes the position of the operator’s seat via
a sprocket. A brake integrated in the motor locks the seat in the de-
sired position. The brake is regulated via the seat reversal brake sole-
noid valve (Y676).
1
006148
1. Electrical motor

9 Frame, body, cab and accessories – 9.3.10 Rotating operator’s seat 27
Reversible operator’s seat, electrical motor,

page
–
replacement
2. Tip the cab.
3. Undo the connector for the electric motor.
4. Remove the four screws that hold the electric motor in place.
5. Remove the electric motor.
6. Installation is in reverse order.
006148
1. Electrical motor
9.3.10 Rotating operator’s seat

Rotating operator’s seat, description
page
–
The rotating operator’s seat is operated by foot. The operator’s seat

can be manually rotated (10 degrees to the left and 40 degrees to the
right) primarily to simplify entering and exiting the machine as well as
to reduce the need to turn the head when driving rearward). The pedal
(on the console) is released with the foot.
This rotating seat console is available in different versions, with or
without doubled pedals.
001625
NOTE
Console for rotating operator’s seat.
Avoid rotating the seat while operating.
9.3.11 Armrest
Armrests, description
page
–
The armrest is fixed to the backrest and is individually adjustable ver-

tically (around the attachment point). Depending on options there is
also an armrest for the left-hand side that can be equipped with:
• Mini-wheel
• Lever steering

28 9 Frame, body, cab and accessories – 9.3.12 Directional valve, reversible operator’s seat
9.3.12 Directional valve, reversible

operator’s seat
Directional valve, reversible operator’s seat,
page
–
description
See section 5 Steering, group 5.2.15 Directional valve, reversible

operator’s seat.
9.3.13 Reversible operator’s seat sensor

Reversible operator’s seat sensor, description
page
–
See section 5 Steering, group 5.2.16 Sensor, reversible opera-

tor’s seat.
9.3.14 Sensor operator in seat

Sensor operator in seat, description
page
–
The operator-in-seat sensor (S230) detects whether the operator’s

seat springs are depressed, which indicates to the control system that
1 the operator’s seat is occupied. This is used to allow the control sys-
tem to indicate with the operator-in-seat buzzer (H853) if the operator
leaves the machine without applying the parking brake. The sensor
also enables the control system to prevent a gear from being engaged
2 if the operator is not in the operator’s seat or to automatically disen-
gage the gear after 3 seconds if the operator leaves the seat with a
gear engaged.
The operator-in-seat sensor (S230) is supplied power by and sends a
voltage signal to the cab control unit (D790-1). The signal can be
checked with the diagnostic menu, see section 8 Control system ,
group 8.4.3.6 CAB, menu 6.
008220
Seat seen from below

1. Sensor operator in seat (S230)
2. Buzzer (H853)

9 Frame, body, cab and accessories – 9.4 Heating, ventilation and air conditioning 29
9.4 Heating, ventilation and air

conditioning
Heating, ventilation and air conditioning,
page
–
description
The heating system controls heating and ventilation of the cab. The
F cab can also be equipped with a climate control system ( ).
The temperature in the cab is thermostat-controlled by the cab control
unit (D790-1). The cab temperature is regulated to the set tempera-
2 ture. The temperature can be set between 16 and 27 °C. The unit is
4 operated with controls on the instrument panel.
D
C Heating system (EHC)
The heating system (EHC) handles heating and ventilation. (The heat-
E E
ing system cannot provide cooling.)
3
The heating system uses heat from the engine’s cooling system via a
heating coil to heat ambient air. The fan forces the ambient air through
the heating coil on through ducts in the cab interior. It is then directed
to the windscreen (defroster) or the feet.
6 A B Climate control system (ECC)
The climate control system (ECC) is responsible for heating, ventila-

tion, cooling and drying. The air is heated in the same way as for the
heating system (EHC).
1 During cooling, ambient air is forced through the evaporator, which
5 G cools the air. The air can then be directed in the same way as for the
000762
heating system.
Principle illustration, climate control system The function of the climate control system is to:
1. Fluid reservoir/filter dryer with built-in pressure • heat the air when it is cold
switch
• dehumidify the air when it is damp
2. Heater and evaporator
3. Fan • clean the air of impurities
4. Expansion valve • cool the air when it is hot
5. Condenser • defrost (defroster function)
6. Compressor
A. High-pressure gas
B. High-pressure fluid
C. Low-pressure fluid
IMPORTANT
D. Low-pressure gas
E. Ambient air for cab ventilation On machines with ECC or AC, it is vital that the engine
F. Heated or cooled air to the cab cooling system is filled with coolant with the right
G. Ambient air for removal of heat concentration of anti-freeze. Otherwise there is a risk
that the air conditioning heating coils will freeze when
the cooling function is used during period when the
heating is completely switched off.

30 9 Frame, body, cab and accessories – 9.4 Heating, ventilation and air conditioning

page
–
2 1 D3 3 26
D1
25
D4
4 ˚C D23
D6
˚C
D5 D15 6
7 D790-1 D790-2 D795
D9
15 D15 D797-R D794
M 16 D21 12 D10
14 22 23
5 ˚C Pa ˚C
M D17
D14 21
19 20 C 24
13
M 18
D13 17
D9 9
M
10
˚C
8 11
Pos Explanation Signal description Reference 006416
1 The temperature switch (S117) sends a Raise: U = 2.0–2.5 V Controls and instruments, overview page 5
voltage signal to the cab control unit Unaffected: U = 0-0.5 V D1: Diagnostic menu, see section 8 Control
(D790-1). system, group 8.4.4.5 CLIMATE, menu 5
Lower: U = 4.5-5.0 V
2 The fan switch (S118) sends a voltage Raise: U = 2.0–2.5 V Controls and instruments, overview page 5
signal to the cab control unit (D790-1). Unaffected: U = 0-0.5 V D2: Diagnostic menu, see section 8 Control
Lower: U = 4.5-5.0 V system, group 8.4.4.5 CLIMATE, menu 5
3 The air distribution switch (S139) sends Scroll up: U = 2.0–2.5 V Controls and instruments, overview page 5
a voltage signal to the cab control unit Unaffected: U = 0 V D3: Diagnostic menu, see section 8 Control
(D790-1). system, group 8.4.4.5 CLIMATE, menu 5
Scroll down: U = 4.5-5.0 V
4 The cab temperature sensor (B775-1) R = 10 kΩ at 25 °C Sensor, cab temperature, description page
sends the cab control unit (D790-1) a 62
voltage signal proportional to the tem- D4: Diagnostic menu, see section 8 Control
perature. system, group 8.4.4.1 CLIMATE, menu 1


5 The blower fan temperature sensor R = 10 kΩ at 25 °C Sensor, temperature outlet fan, description
(B775-2) sends the cab control unit page 61
(D790-1) a voltage signal proportional to D5: Diagnostic menu, see section 8 Control
temperature. system, group 8.4.4.2 CLIMATE, menu 2
6 The ambient temperature sensor (B774) R = 10 kΩ at 25 °C Sensor, ambient temperature, description

sends the cab control unit (D790-1) a page 63
voltage signal proportional to tempera- D6: Diagnostic menu, see section 8 Control
ture. system, group 8.4.4.2 CLIMATE, menu 2
7 The cab control unit (D790-1) regulates Checked by control sys- Section 11 Common electrics, group
temperature and air distribution with sig- tem, error shown with er- 11.5.3.1 Cab control unit (D790-1)
nals from sensors and controls. ror code.
8 The engine produces heat when run- - -

ning. It is cooled with the cooling system.
The heat from the cooling system is
used to heat the cab air.
9 The cab control unit (D790-1) controls U = 0.5–4.5 V Water valve, description page 47
the water valve (Y673), which directs hot D9: Diagnostic menu, see section 8 Control
water to heat exchanger heating. system, group 8.4.4.7 CLIMATE, menu 7
The water valve’s opening (%) is sent and 8.4.4.4 CLIMATE, menu 4
back to the cab control unit (D790-1).
This gives information for controlling the
water valve’s position.
10 The engine temperature sensor sends Checked by control sys- Section 1 Engine
the engine control unit (D794) a voltage tem, error shown with er- D10: Diagnostic menu, see section 8 Control
signal proportional to engine tempera- ror code. system, group 8.4.4.2 CLIMATE, menu 2
ture.
11 Heat exchanger heat adds heat to the - Heat exchanger heat, description page 44
cab air. Heat is transferred from the en-
gine’s cooling system to the cab air.
12 The engine control unit (D794) transmits Checked by control sys- Section 11 Common electrics, group
engine temperature in the cooling system, error shown with er- 11.5.3.10 Engine control unit (D794)
tem on the CAN bus. ror code.
13 The cab control unit (D790-1) controls Checked by control sys- Fresh air filter or recirculation damper, de-
the recirculation actuator motor (M612) tem, error shown with er- scription page 38
which sets the fresh air or recirculation ror code. D13: Diagnostic menu, see section 8 Control
damper in the required position. system, group 8.4.4.6 CLIMATE, menu 6
14 The cab control unit (D790-1) controls Checked by control sys- Cab fan, description page 41
the fan motor (M657), which increases tem, error shown with er- D14: Diagnostic menu, see section 8 Control
airflow in the cab. ror code. system, group 8.4.4.6 CLIMATE, menu 6


15 The cab control unit (D790-1) controls U = 0.5–4.5 V Air distributor, description page 59
the actuator motor (Y672), which sets D15: Diagnostic menu, see section 8 Control
the air distributor to the required posi- system, group 8.4.4.8 CLIMATE, menu 8
tion. and 8.4.4.4 CLIMATE, menu 4
The air distributor’s position is sent back
to the cab control unit (D790-1). This
gives information for controlling the air
distributor’s position.
16 The frame control unit (D797-1) controls Checked by control sys- Section 11 Common electrics, group
AC compressor engagement. tem, error shown with er- 11.5.3.3 Frame control unit (D797-1)
ror code.
17 The frame control unit (D797-1) supplies U = 24 V AC compressor, description page 48

voltage to the compressor’s solenoid D17: Diagnostic menu, see section 8 Control
valve (645). system, group 8.4.4.6 CLIMATE, menu 6
18 The compressor draws gaseous refrig- - AC compressor, description page 48

erant from the evaporator, compresses
it, and forces it on to the condenser.
19 The condenser cools the refrigerant. - AC compressor, description page 48

The gaseous refrigerant condenses to
liquid form and is pumped on in the cir-
cuit.
20 The moisture filter absorbs any moisture - Moisture filter, description page 53
from the cooling circuit. The fluid reser-
voir stores the refrigerant.
21 The pressure switch (S246) sends a sig- U = 24 V Pressure switch, description page 53
nal to the rear frame control unit (D797- D21: Diagnostic menu, see section 8 Control
R) if the pressure in the system becomes system, group 8.4.4.3 CLIMATE, menu 3
abnormally high or low.
22 The expansion valve adjusts the amount - Expansion valve, description page 54
of refrigerant that is let in to the evapora-
tor. If the temperature in the evapora-
tor’s outlet pipe increases, the
evaporator valve increases flow of refrig-
erant so that heat dissipation in the
evaporator increases.
23 The refrigerant circuit temperature sen- R = 10 kΩ at 25 °C Sensor, temperature in refrigerant, descrip-

sor sends the cab control unit (D790-1) tion page 56
a voltage signal proportional to tempera- D23: Diagnostic menu, see section 8 Control
ture. system, group 8.4.4.2 CLIMATE, menu 2.
24 Heat exchanger cooling dissipates heat - Evaporator, description page 58

from the cab air. Heat is transferred from
the air to the refrigerant and transforms
the refrigerant to a gaseous state.


25 The defroster switch on the KIT control Checked by control sys- Section 11 Common electrics, group
unit (D790-2) activates the defroster pro- tem, error shown with er- 11.5.3.11 KIT control unit (D790-2)
gram of the climate control system for six ror code.
minutes.
26 The KID control unit (D795) shows the Checked by control sys- Section 11 Common electrics, group
heating and ventilation settings in the tem, error shown with er- 11.5.3.12 KID control unit (D795)
display. ror code.

page
–
checking
2 Navigate to the service menu and press Enter.
000056
3 Enter code for diagnosis. Code is obtained from Kalmar Indus-

tries Support.
1 23
4 5 NOTE
000060
The code decides which service menu is to be activated (Di-

agnostic test, Initiation, Calibration, or Service indication).
4 Select CLIMATE.
DIAGNOSIS
CAN/POWER LIGHTS CAB Menu 1
CLIMATE HYD ENGINE
004998
OLS EXTRA
5 Check of desired temperature, inside temperature sensor and

DIAG CLIMATE 1(8) water valve.
REQUIRED TEMP XXX REQUIRED TEMP: 160 (16.0 °C) for max. cooling and 280
PRESENT TEMP XXX (28.0 °C) for max. heating. The setting is changed with the tem-
000132
WATER VALVE FEEDB. XXX perature switch.

PRESENT TEMP shows the temperature inside the cab. This is
measured by Sensor cab temperature (located down to the right
on the instrument panel, behind the rubber bushing). Blowing
through the hole should increase the value.
WATER VALVE FEEDB. should show 0 (closed) when the re-
quested temperature is 160 and 100 (open) when the requested
temperature is 280. The water valve is located under the cab.

Menu 2
6 Check of Sensor temperature outlet fan (B775-2), engine temper-
DIAG CLIMATE 2(8) ature, Sensor outdoor temperature (B774), Check of Sensor tem-
TEMP COIL XXX perature refrigerant (B775-1).
TEMP COOLANT XXX
TEMP AMBIENT XXX TEMP COIL: temperature that the air has in the air distributor is
000133
TEMP DE-ICE XXX measured by Sensor temperature outlet fan (B775-2).
TEMP COOLANT: engine temperature sent on the CAN-bus.
TEMP AMBIENT: outdoor temperature measured by Sensor out-
door temperature (B774).
TEMP DE-ICE: cooling circuit’s temperature measured by Sen-
sor temperature refrigerant (B775-1). If the compressor is activat-
ed the value will be low. However, if heat has been selected and
the compressor is deactivated, the value will almost be equal to
TEMP COIL.
Menu 3
7 (Only machines with ECC)

DIAG CLIMATE 3(X)
PRESENT INPUT SIGNAL Checks that refrigerant circuit is filled.
PRESSURE SWITCH X PRESSURE SWITCH: 0 = not filled 1 = filled.
OPT DOOR SWITCH X
006865
The sensor is located on the dryer filter which is fitted right rear in
the frame.
Menu 4
8 Checks Water valve (Y673) and Air distributor (Y642).
DIAG CLIMATE 4(8)
WATER VALVE: should work between 1.0-1.24 V and 2.95-3.2
WATER VALVE XX.XXV V. This is checked by turning the temperature control and chang-
DRAUGHT VALVE XX.XXV ing temperature setting from min. to max.
000135
DRAUGHT VALVE: should work in the range 1.0-4.0 V. The dif-

ference between min. and max. should be approx 1 V. This is
checked by changing the air distribution from floor to front wind-
shield. At the same time, feel with your hand so that air blows
through different vents.
NOTE
Air to the round panel vents is not controlled by the air con-
ditioning unit.
Menu 5
9 Checks switches for temperature, air distribution and fan speed.
DIAG CLIMATE 5(8)
REQUIRED TEMP: resting position U = 0 V; raise U = 2-2.5 V;
REQUIRED TEMP XX.XXV lower U = 4.5-5 V.
REQ. DRAUGHT XX.XXV REQ. DRAUGHT: resting position U = 0 V; against windshield U
000136
REQ. FAN SPEED XX.XXV = 2-2.5 V; against floor U = 4.5-5 V.

REQ. FAN SPEED: resting position U = 0 V; raise U = 2-2.5 V;
lower U = 4.5-5 V.

Menu 6
10 Checks cab fan (M657), fresh air and recirculation damper
DIAG CLIMATE 6(8)
PRESENT OUTPUT SIGNAL (M612) and compressor’s electromagnetic clutch (M645) .
FAN SPEED XXX FAN SPEED: increase and decrease fan speed, value should in-
RECIRKULATION XY crease from 0 to 255 in steps.
000137
COMPRESSOR XY
RECIRCULATION: press in the bypass switch (S1005) (on the
panel for load handling functions). When checking, the display
should show "11". Check that the damper really moves as it
should by removing the fresh air filter at the front of the climate
control system casing and feeling with your hand.
(Only machines with ECC)

COMPRESSOR: lower temperature setting to max. cooling, after
approx. 45 seconds the compressor will be activated and the dis-
play should show "11".
NOTE
Compressor activation can only be tested when the engine
is running and the system is filled.
Menu 7
11 Checks direction selector for Water valve (Y673).
DIAG CLIMATE 7(8) CLOCKWISE: When temperature is increased and the water
OUTPUT WATER VALVE valve opens shows "CLOCKWISE 11 11" and "COUNTER-
CLOCKWISE XY XY
ANTI-CLOCKWISE XY XY CLOCKWISE 00 11".
COUNTER-CLOCKWISE: When temperature is lowered and the
water valve closes shows "CLOCKWISE 00 11" and "COUNTER-
24V CLOCKWISE 11 11".
NOTE
The ones are only showed for a moment when the water
valve changes position, zeros are shown when the valve is
M not changing position. The water valve does not open if en-
gine temperature is low, or if outdoor temperature is high.
000138
0V

Menu 8
12 Checks direction selector for air distributor.
DIAG CLIMATE 8(8)
CLOCKWISE: when the air is directed against the windshield and
OUTPUT DRAUGHT VALVE
CLOCKWISE XY XY the air distributor changes position shows "CLOCKWISE 00 11"
ANTI-CLOCKWISE XY XY and "COUNTER-CLOCKWISE 11 11".
COUNTER-CLOCKWISE: when the air is directed against the
feet and the air distributor changes position shows "CLOCKWISE
24V 11 11" and "COUNTER-CLOCKWISE 00 11".
NOTE
The ones are only shown for a moment when the air distrib-
utor changes position, zeros are shown when the air distrib-
M utor is not changing position.
000139
0V

9 Frame, body, cab and accessories – 9.4.1 Fresh air filter 37
9.4.1 Fresh air filter

Fresh air filter, description
page
–
The fresh air filter is located under a cover in the external unit for fresh
air intake into the cab - in front of the cab fan. A finer filter can be used
( ), but this may affect maximum airflow.
1 004999
Fresh air intake, cab

1. Fresh air filter
2. Fresh air and recirculation damper

38 9 Frame, body, cab and accessories – 9.4.2 Fresh air and recirculation damper
9.4.2 Fresh air and recirculation damper

Fresh air filter or recirculation damper, description
page
–
The damper is controlled electrically and controls the air between fully
open for fresh air to recirculation of air. The damper is located in the
external unit for fresh air intake into the cab.
Control system, group 8.4.4.6 CLIMATE, menu 6 .
2 004999

1. Fresh air filter
2. Fresh air and recirculation damper

9 Frame, body, cab and accessories – 9.4.2 Fresh air and recirculation damper 39
Motor, fresh air filter or recirculation damper,

page
–
replacement
2 Remove the wiper arms.
3 Remove the nuts which hold the wiper motor in the protective
plate.
4 Remove the protective plate.
5 Remove the fresh air filter.

40 9 Frame, body, cab and accessories – 9.4.2 Fresh air and recirculation damper
6 Remove the bolts which secure the arm and motor in the plate.
7 Detach the connector from the motor.
8 Replace the motor.
9 Fit in the reverse order. Tighten the wiper arm to 16-20 Nm.

9 Frame, body, cab and accessories – 9.4.3 Cab fan 41
9.4.3 Cab fan

Cab fan, description
page
–
The cab fan is located in the external unit for fresh air intake into the
cab. The fan consists of two single fans that are driven by a motor.
Control system, group 8.4.4.6 CLIMATE, menu 6.
1
003209

1. Cab fan
Cab fan, replacement

page
–


42 9 Frame, body, cab and accessories – 9.4.3 Cab fan
3 Remove the bolts which secure the wiper motor in the protective
plate.
5 Detach the washer hose from the protective plate.

9 Frame, body, cab and accessories – 9.4.3 Cab fan 43
7 Remove the bolts which secure the plate and cab fan.
8 Detach the connector from the cab fan.

9 Remove the cab fan.
10 Replace the cab fan.

44 9 Frame, body, cab and accessories – 9.4.4 Heat exchanger heat
9.4.4 Heat exchanger heat

Heat exchanger heat, description
page
–
The heat from the engine’s coolant is transmitted to the cab via the
heat exchanger. The heat exchanger is located behind the fan in the
external unit for fresh air intake into the cab.
1, 2
3
003210

1. Heat exchanger heat
2. Heat exchanger cooling
3. Expansion valve and sensor for refrigerant temper-
ature

9 Frame, body, cab and accessories – 9.4.4 Heat exchanger heat 45
Heat exchanger, cooling/heating, replacement

page
–
WARNING
Personal injury, environmental damage
Read the safety instructions for refrigerant, see sec-

tion B Safety.

2 Drain the AC system of R134a refrigerant.
IMPORTANT
Working on the air conditioning requires special au-
thorization.
3 Detach the AC system hoses and the coolant hoses.

5 Remove the nuts which hold the wiper motor in the protective
plate.

46 9 Frame, body, cab and accessories – 9.4.4 Heat exchanger heat
9 Remove the plate frame.
10 Remove the cab fan.
11 Remove the heat exchanger cover plate.

9 Frame, body, cab and accessories – 9.4.5 Water valve 47
12 Detach all fluid inlets and outlets from the heat exchanger.
13 Lift out the heat exchanger carefully.
14 Replace the heat exchanger.
16 Check for leaks and refill the AC-system with refrigerant R134a,
with the intended equipment.
For volume, see section F Technical data.
IMPORTANT
Connection points for cooling hoses. Working on the air conditioning requires special au-
thorization.
9.4.5 Water valve

Water valve, description
page
–
The water valve controls the climate control system’s capacity for
heating from 0 (closed valve) to 100% (open valve). The water valve
is electrically controlled.
The signal can be checked from the diagnostic menu, see 8 Control
system, group 8.4.4.1 CLIMATE, menu 1, 8.4.4.4 CLIMATE, menu 4
and 8.4.4.7 CLIMATE, menu 7.
007863
Water valve position under cab floor (from below)

48 9 Frame, body, cab and accessories – 9.4.6 Engine temperature sensor
Water valve, replacement

page
–

2 Detach the connector from the water valve.
3 Stop the flow of fluid to and from the water valve using hose
pinch-off pliers.
4 Detach the coolant hoses from the water valve.
5 Remove the water valve from the cab floor.
6 Replace the water valve.
8 Check coolant level.
1. Water valve
2. Steering valve
9.4.6 Engine temperature sensor

Sensor, engine temperature, description
page
–
The coolant temperature sensor sits on the engine and detects engine
coolant temperature. See supplier documentation, engine.
For location, see section 1 Engine.
9.4.7 Compressor
AC compressor, description
page
–
NOTE
For tightening torque of refrigerant hoses and pressure switch,
see section F Technical data.
The compressor drives the climate control system by working as a
pump. It draws in cold, low-pressure gas from the evaporator, com-
presses the gas which then becomes warm, and then forces out high-
pressure gas to the condenser.
The compressor is driven by V-belts directly by the machine’s engine.
Activation and deactivation of the compressor is handled by an elec-
tromagnetic clutch, which is controlled by a thermostat.
007866

9 Frame, body, cab and accessories – 9.4.7 Compressor 49
AC compressor, replacement
page
–
2
WARNING

1
tion B Safety.
007865
2 Drain the AC system of R134a refrigerant.
The illustration depicts the compressor for Volvo
TAD760VE
1. Compressor IMPORTANT
2. Rigging screw (belt tensioner)
thorization.
3 Detach the coolant hoses from the compressor.

4 Loosen the turnbuckle so that the compressor belt is released.
5 Undo the hose couplings and detach the hoses from the com-
pressor intake and outlet. Plug the connections immediately to
prevent contamination.
6 Remove the bolts which secure the compressor.
7 Drain the oil from the old compressor (through the intake and out-
let connections) and the hoses. Measure the oil quantity.
8 Drain the oil from the new compressor.
9 Fill the new compressor with the same quantity of oil as was
drained from the old compressor - minimum 0.1 litre.
NOTE
Fill new oil through the compressor’s suction connection.
10 Fit the new compressor and other equipment in reverse order.
For volume, see the plate for the climate control system.
IMPORTANT
thorization.

50 9 Frame, body, cab and accessories – 9.4.7 Compressor
Pulley and electromagnetic clutch, replacement

page
–
There is no need to drain refrigerant from the system before replace-

ment.
2 Slacken the belt tensioner and remove the drive belt.
3 Remove the screw from the centre of the pulley.
006263
4 Remove the locking washer and the outer lock ring.

1
2
006264
1. Lock ring
2. Locking washer
5 Remove the groove.

1
006265
1. Groove

9 Frame, body, cab and accessories – 9.4.8 Condenser 51
6 Remove the three screws securing the electromagnetic clutch.
006266
7 Remove the electromagnetic clutch.
1 9 Check the function.
006267
1. Electromagnetic clutch
9.4.8 Condenser
Condenser, description
page
–
The condenser is located on the radiator in the engine compartment.

The function of the condenser is to convert the hot, high-pressure gas
from the compressor to liquid form. Pipes and cooling fins in the con-
denser battery absorb the heat, which is dissipated with a fan.
The temperature of the refrigerant in the condenser varies from ap-
prox. 50 °C to 70 °C and the pressure varies between 12 and 14 bar
depending on ambient temperature and airflow through the condens-
er. When the refrigerant has been condensed to liquid, it is directed on
to the fluid reservoir/filter dryer.
007867

52 9 Frame, body, cab and accessories – 9.4.8 Condenser
Condenser, replacement
page
–
WARNING

tion B Safety.
1. Radiator 2 Drain the AC system of R134a refrigerant.

2. Condenser
IMPORTANT
thorization.
3 Detach the inlet and outlet hoses from the condenser.

4 Remove the bolts which secure the condenser at the top edge
and lift the condenser out in a suitable way.
5 Replace the condenser, fitting it in the reverse order.
IMPORTANT
thorization.

9 Frame, body, cab and accessories – 9.4.9 Moisture filter 53
9.4.9 Moisture filter

Moisture filter, description
page
–
The moisture filter collects the liquid refrigerant, binds moisture and fil-
ters impurities. The reservoir functions as an expansion tank in the
2 3 cooling circuit.
1
When the refrigerant has passed through the dryer in the bottom of the
fluid reservoir, it rises through a standpipe. Through a sight glass, it is
possible to check that flow is without bubbles and that the system is
adequately filled with refrigerant.
007864
1. Fluid reservoir, moisture filter

2. Pressure switch
3. Sight glass
9.4.10 Pressure switch

Pressure switch, description
page
–
NOTE
2 3 For tightening torque of refrigerant hoses and pressure switch,
1
see section F Technical data.
The pressure switch cuts off the current to the compressor’s electro-
magnetic clutch if the pressure in the cooling circuit becomes abnor-
mally high or low.
007864

2. Pressure switch
3. Sight glass

54 9 Frame, body, cab and accessories – 9.4.11 Expansion valve
Pressure switch, replacement

page
–
WARNING
2 3
1 Personal injury, environmental damage

tion B Safety.

2 Drain the machine of refrigerant, R134a.
IMPORTANT
007864
thorization.

2. Pressure switch 3 Disconnect the connector from the pressure switch.
3. Sight glass 4 Unscrew the pressure switch from its mounting.
5 Replace the pressure switch.
IMPORTANT
thorization.
9.4.11 Expansion valve

Expansion valve, description
page
–
The expansion valve is the part in the circuit that separates the high-
pressure side from the low-pressure side. The refrigerant arrives at the
expansion valve under high pressure and leaves it under low pres-
sure. After the expansion valve, the refrigerant converts to a gaseous
state and is transported to the compressor once again.
The amount of refrigerant that passes the evaporator varies depend-
ing on the heat load. The valve works from fully open to fully closed
and searches between these for an optimal evaporation point.

9 Frame, body, cab and accessories – 9.4.11 Expansion valve 55
Expansion valve, replacement

page
–
WARNING

tion B Safety.

2 Drain the AC system of refrigerant.
IMPORTANT
thorization.
3 Detach the AC system hoses.

4 Detach the coolant hoses.
5 Remove the heat exchanger for cooling/heating to access the ex-
pansion valve, see Heat exchanger, cooling/heating, replace-
ment page 45.
6 Replace the expansion valve.
IMPORTANT
thorization.

56 9 Frame, body, cab and accessories – 9.4.12 Sensor temperature refrigerant
9.4.12 Sensor temperature refrigerant

Sensor, temperature in refrigerant, description
page
–
Refrigerant temperature sensor (position 2) detects the refrigerant

temperature in the heat exchanger cooling. This is used to control the
air conditioning.
1
3
005001
1. Sensor cab temperature

2. Sensor temperature refrigerant
3. Sensor temperature outlet fan
Sensor, refrigerant temperature, replacement

page
–
WARNING
Personal injury, environmental damage.

tion B Safety.
NOTE
Requires special authorization.
2 Drain the AC system of refrigerant.
IMPORTANT
thorization.
3 Detach the AC system hoses from the heat exchanger.

4 Detach the coolant hoses from the heat exchanger.
5 Detach the heat exchanger to access the refrigerant temperature
sensor, see Heat exchanger, cooling/heating, replacement page
45.
6 Replace the temperature sensor.

9 Frame, body, cab and accessories – 9.4.12 Sensor temperature refrigerant 57

IMPORTANT
thorization.

58 9 Frame, body, cab and accessories – 9.4.13 Heat exchanger cooling
9.4.13 Heat exchanger cooling

Evaporator, description
page
–
The heat exchanger for cooling consists of pipes and cooling fins. The
cab air is cooled as it passes through the cooling heat exchanger. The
heat exchanger is located behind the fan in the external unit for fresh
air intake into the cab.
1, 2
3
003210

1. Heat exchanger heat
2. Heat exchanger cooling
3. Expansion valve and sensor for refrigerant temper-
ature
Heat exchanger cooling, replacement

page
–
See Heat exchanger, cooling/heating, replacement page 45.

9 Frame, body, cab and accessories – 9.4.14 Air distributor 59
9.4.14 Air distributor

Air distributor, description
page
–
The air distributor controls the air between defroster and floor and is
located behind the panel inside the cab. The damper is controlled elec-
trically by the control system.
Control system, group 8.4.4.4 CLIMATE, menu 4 and 8.4.4.5 CLI-
MATE, menu 5 and 8.4.4.8 CLIMATE, menu 8.
002230
Air distributor, replacement

page
–

3 Remove the steering wheel shaft cover.
4 Detach the steering wheel shaft and angle it back against the op-
erator’s seat.
5 Remove the lower cover in front of the pedal bracket.
6 Detach the air hoses from the air distributor and detach the con-
nector.
1. Instrument panel
2. Steering wheel shaft adjustment
3. Lower protective cover
7 Remove the air distributor from its mounting.
8 Replace the air distributor, fitting it in the reverse order.
Air distributor

60 9 Frame, body, cab and accessories – 9.4.15 Air vents
9.4.15 Air vents

Air vents, description
page
–
There are a number of fixed air vents in the cab’s interior: at the front
of the doors and the defroster for the windshield. There are also two
adjustable air vents (flow and direction) in the instrument panel’s out-
side corners.
There is an air inlet towards the cab’s lower part (floor).
001839
Defroster nozzles, replacement

page
–

2 Remove the air damper manually.
3 Remove the bolts which hold the other part of the defroster noz-
zle in the dashboard.

9 Frame, body, cab and accessories – 9.4.16 Sensor temperature outlet fan 61
4 Detach the air hose from the defroster nozzle.

5 Replace the defroster nozzle.
9.4.16 Sensor temperature outlet fan

Sensor, temperature outlet fan, description
page
–
The outlet fan temperature sensor (position 3) detects the temperature

of the air that blows out in the defroster nozzles. The air conditioning
is controlled by signals from the following sensors:
1 3. Sensor temperature outlet fan
3 The signal can be checked from the diagnostic menu, see section 8
005001
Outlet fan temperature sensor, replacement

page
–

3 Remove the lower protective cover in front of the steering wheel
shaft.
4 Detach the steering wheel shaft and angle it back against the op-
erator’s seat.
1. Instrument panel
2. Steering wheel shaft adjustment
3. Lower protective cover

62 9 Frame, body, cab and accessories – 9.4.17 Sensor cab temperature
5 Detach the temperature sensor from the air distributor.

Air distributor including temperature sensor.
9.4.17 Sensor cab temperature

Sensor, cab temperature, description
page
–
The cab temperature sensor (position 1) detects the temperature of

the air in the cab.
1
3
005001

3. Sensor temperature outlet fan
Cab temperature sensor, replacement

page
–


9 Frame, body, cab and accessories – 9.4.18 Sensor outdoor temperature 63
3 Detach the hose from the temperature sensor.

4 Detach the connector from the temperature sensor.
5 Remove the temperature sensor.
007985
9.4.18 Sensor outdoor temperature

Sensor, ambient temperature, description
page
–
The ambient temperature sensor detects the temperature of the air

outside the cab.
Sensor outdoor temperature
Ambient temperature sensor, replacement

page
–

2 Detach the connector from the temperature sensor.
3 Remove the temperature sensor from its mounting in the cab.

64 9 Frame, body, cab and accessories – 9.4.19 Pause heater
9.4.19 Pause heater

Pause heater, description
page
–
1
Pause heating is an option for the heating unit, which uses residual
heat in the engine's cooling system to keep the cab warm.
An extra electrically operated water pump pumps the coolant through
the heater unit when the engine is stopped. The cabin fan forces air
into the cab. The pause heater is automatically switched off when the
temperature in the cab is six degrees below the value set on the cli-
mate control system. The pause heater is activated with the pause
2 heater switch when the ignition is on.
3 004909
1. Pause heater switch (S0_OPT-1)

2. Control unit cab (D790-1)
3. Circulation pump pause heater (M667)

9 Frame, body, cab and accessories – 9.5 Wiper/washer system 65
9.5 Wiper/washer system

Wiper/washer system, description
page
–
The wipers automatically switch off 2 minutes after the operator has
left the operator’s seat.
9.5.1 Wiper front

Wiper, front, description
page
–
The front wiper is the parallel wiper type, i.e. the wiper blade is moved
in a constant vertical manner over the windscreen.
9.5.2 Wiper roof

Wiper, roof, description
page
–
Wiper roof are of the type sector wiper. Wiping angle is approx. 180
degrees.
9.5.3 Wiper rear

Wiper, rear, description
page
–
The rear wiper is a sector wiper type. The wiping angle is approx. 180
degrees.
9.5.4 Washer motor and reservoir

Washer motor and reservoir, description
page
–
Washer motors are located on the washer fluid reservoir. There are
non-return valves on the lines from the reservoir to the washer noz-
zles, preventing the washer fluid from draining back in the line be-
tween washings. This minimizes the time from activation of switch
washing and washer fluid spraying on the windshield.
The washer nozzles are mounted on the wiper arms.
Control system, group 8.4.3.1 CAB, menu 1.

66 9 Frame, body, cab and accessories – 9.5.5 Wiper motor, front
Washer motor and container, replacement

page
–

2 Remove the protection over the washer fluid reservoir.
3 Drain the washer fluid from the container.
4 Remove the washer motors from the fluid reservoir.
5 Remove the bolts which secure the fluid container in the cab wall.
6 Change the washer fluid reservoir. Change the washer motor, if
needed.
003619
A B
A. Washer fluid reservoir
B. Washer motors
9.5.5 Wiper motor, front

Wiper motor, front, description
page
–
The wiper motor drives the front windscreen wiper. The wiper arm is
mounted on the motor. The motor produces the movement of the wip-
er.
Front wiper motor, replacement

page
–

3 Remove the nuts which hold the motor in the protective plate.

9 Frame, body, cab and accessories – 9.5.6 Wiper motor, roof 67
6 Remove the nuts which hold the motor in the cab.

7 Detach the connector from the wiper motor.
8 Replace the motor.
9 Fit in the reverse order. Tighten the wiper arms to 16-20 Nm.
9.5.6 Wiper motor, roof

Wiper motor, roof, description
page
–
The wiper motor drives the roof window’s wiper. The wiper arm is
mounted on the motor. The motor produces the movement of the
wiper.
Wiper motor (roof), replacement

page
–

2 Remove the plastic cover.
3 Detach the washer hose and the connector to the wiper motor.

68 9 Frame, body, cab and accessories – 9.5.7 Wiper motor, rear
4 Undo the lock nut securing the wiper arm and disconnect the
washer fluid hose.
5 Remove and replace the wiper motor.
9.5.7 Wiper motor, rear

Wiper motor, rear, description
page
–
The wiper motor drives the rear window wiper. The wiper arm is
mounted on the motor. The motor produces the movement of the wip-
er.
Rear wiper motor, replacement

page
–

2 Remove the panels behind the operator’s seat.
3 Remove the screws holding the motor’s plastic cover.
4 Detach the connector from the motor.

5 Raise the plastic cover and remove the nut securing the wiper
arm. Disconnect the washer hose.

9 Frame, body, cab and accessories – 9.5.7 Wiper motor, rear 69
6 Remove the screws securing the motor and the lock nut on the
motor.
7 Replace the wiper motor.
8 Fit in the reverse order. Tighten the wiper arms to 16-20 Nm.

70 9 Frame, body, cab and accessories – 9.6 Lighting system
9.6 Lighting system

Lighting system, function description
page
–
Work lights are shut off automatically after 5 minute’s idling in order to
prevent discharge of the batteries. Auxiliary work lights are shut off af-
ter 2 minutes. Lighting is activated automatically again when the oper-
ator sits in the seat, a gear is selected or the accelerator pedal is
pressed.
NOTE
It is important that the right type of bulb is used for each area. See
1 2 4 3
D1 D2 D4 D3 7
8
D13 9
12
5 D7
D5 13 13
16
D16 D9
14
15 M D14
D15 D790-1 D790-2 D8
18 6, 11 27 10
D19 D20 D21 D22 D23 D797-1 D797-2
17
Pa D28 D29
D24 D30
D17
D25 D31
009717
D26 D32
19 20 21 22 23 24 25 26 28 29 30 31 32

1 The switch for cab roof work lights (S105-1) Switch in ON position: U D1: Diagnostic menu, see section 8
sends a voltage signal to the cab control unit = 24 V Control system group 8.4.2.12
(D790-1). LIGHTS, menu 12
2 The switch for mast work lights (S105-3) sends Switch in ON position: U D2: Diagnostic menu, see section 8
a voltage signal to the cab control unit (D790- = 24 V Control system, group 8.4.2.10
1). LIGHTS, menu 10
3 The headlights switch (S100) sends a voltage Switch in ON position: U D3: Diagnostic menu, see section 8
signal to the cab control unit (D790-1). = 24 V Control system, group 8.4.2.1
LIGHTS, menu 1
4 The revolving beacon switch (S110) sends a Switch in ON position: U D4: Diagnostic menu, see section 8
voltage signal to the cab control unit (D790-1). = 24 V Control system, group 8.4.2.6
LIGHTS, menu 6

9 Frame, body, cab and accessories – 9.6 Lighting system 71
5 The door NC switch (S266-LE & S266-RI) Door open: U = 24 V Interior lighting cab, description page
sends a voltage signal to the cab control unit 78
(D790-1). D5: Diagnostic menu, see section 8
Control system, group 8.4.2.9
LIGHTS, menu 9
6 The cab control unit (D790-1) transmits a Checked by control sys- Section 11 Common electrics, group
"switch on lights" message on the CAN bus. tem, error shown with 11.5.3.1 Cab control unit (D790-1)
error code.
7 The multi-function lever (S162) sends a volt- Lever in high beam posi- Gear and multi-function lever, descrip-
age signal to the KIT control unit (D790-2). tion: US162/56a = 24 V tion page 12
D7: Diagnostic menu, see section 8
LIGHTS, menu 3
8 The direction indicator lever (S161) sends a Left: US161/6 = 24 V D8: Diagnostic menu, see section 8
voltage signal to the KIT control unit (D790-2). Control system, group 8.4.2.4
Right: US161/1 = 24 V
LIGHTS, menu 4
9 The interior lighting switch of the KIT control Checked by control sys- D9: Diagnostic menu, see section 8
unit (D790-2) sends a voltage signal to the KIT tem, error shown with Control system, group 8.4.2.9
control unit (D790-2). error code. LIGHTS, menu 9
10 The KIT control unit (D790-2) transmits a Checked by control sys- Section 11 Common electrics, group
"switch on lights" message on the CAN bus. tem, error shown with 11.5.3.11 KIT control unit (D790-2)
error code.
11 The cab control unit (D790-1) supplies voltage Checked by control sys- Section 11 Common electrics, group
to the lights in and around the cab. tem, error shown with 11.5.3.1 Cab control unit (D790-1)
error code.
12 The relay for cab roof work lights (K3017-1 and UK3017/30 = 24 V Working lights, cab, description page
K3017-2) is activated when the cab roof work 77
UK3017/85 = 0 V
lights are activated. It supplies voltage to the
cab roof work lights (E406L-1 E406R-1, Cab roof work lights on:
E406L-2 & E406R-2). UK3017/86 = 24 V
UK3017/87 = 24 V
Cab roof work lights off:

UK3017/86 = 0 V
UK3017/87 = 0 V
13 The cab roof work lights (E406L-1 E406R-1, Light on: U = 24 V Working lights, cab, description page
E406L-2 & E406R-2) come on when the cab 77
roof work lights are activated. D13: Diagnostic menu, see section 8
LIGHTS, menu 12
14 The white reversing lights (E405L & E405R) Light on: U = 24 V Reversing light, description page 76
come on when reverse gear is selected. D14: Diagnostic menu, see section 8
LIGHTS, menu 8

15 Rotating beacon (H428) is lit when rotating Light on: U = 24 V Rotating beacon, description page 76
work light is activated. D15: Diagnostic menu, see section 8
LIGHTS, menu 6
16 Interior lighting (E434-1) comes on when a Light on: U = 24 V Interior lighting cab, description page
door is opened or if activated when the switch 78
on the KIT control unit (D790-2). D16: Diagnostic menu, see section 8
LIGHTS, menu 9
17 The brake light NO switch (S216) sends a volt- Brake pressure over 0.2 Section 4 Brakes, group 4.3.8 NO
age signal to the frame control unit (D797-1). MPa: U = 24 V (normally open) switch, brake lights
LIGHTS, menu 7
18 The frame control unit (D797-1) supplies volt- Checked by control sys- Section 11 Common electrics, group
age to the machine lights. tem, error shown with 11.5.3.2 Frame control unit (D797-1)
error code.
19 The direction indicators (H422, H423, H426 & Light on: U = 24 V Driving direction indicator, description
H427) come on when they or the warning lights page 76
are activated. D19: Diagnostic menu, see section 8
LIGHTS, menu 5
20 The running lights (H416-1, H416-2, H417-1 & Light on: U = 24 V Running lights, description page 75
H417-2) come on together with the headlights. D20: Diagnostic menu, see section 8
LIGHTS, menu 2
21 Headlights low beams (E400L & E400R) are lit Light on: U = 24 V Headlights, description page 75
when headlights are activated. D21: Diagnostic menu, see section 8
LIGHTS, menu 3
22 Headlights high beam (E402L-1 & E402R-1) Light on: U = 24 V Headlights, description page 75
are lit when high beam is activated. D22: Diagnostic menu, see section 8
LIGHTS, menu 3
23 Tail lights (H412L & H412R) red are lit when Light on: U = 24 V Tail light, description page 75
headlights are activated. D23: Diagnostic menu, see section 8
LIGHTS, menu 2
24 Brake lights (H411L & H411R) are lit when the Light on: U = 24 V Brake light, description page 75
brake is activated. D24: Diagnostic menu, see section 8
LIGHTS, menu 8

9 Frame, body, cab and accessories – 9.6 Lighting system 73
25 The mast work lights (E404L-1 & E404R-1) Light on: U = 24 V Mast working lights, description page
come on when activated. 77
LIGHTS, menu 10
26 The auxiliary mast work lights (E404L-4 & Light on: U = 24 V Mast working lights, description page
E404R-4) come on when the mast work lights 77
The front wing auxiliary work lights (E404L-4 & Control system, group 8.4.2.11
E404R-4) come on when the cab roof work LIGHTS, menu 11
lights are activated.
27 The frame control unit (D797-2) supplies volt- Checked by control sys- Section 11 Common electrics, group
age to the machine lights. tem, error shown with 11.5.3.3 Frame control unit (D797-2)
error code.
28 The auxiliary mast work lights (E404L-2 & Light on: U = 24 V Mast working lights, description page
E404R-2) come on when the mast work lights 77
The front wing auxiliary work lights (E404L-2 & Control system, group 8.4.2.11
E404R-2) come on when the cab roof work LIGHTS, menu 11
lights are activated.
29 With reversed operator’s seat: Headlights, low Light on: U = 24 V Headlights, description page 75
beam rear (E401L & E401R) come on when D29: Diagnostic menu, see section 8
the headlights are activated. Control system, group 8.4.11.1 VBFS,
menu 6
30 With reversed operator’s seat: Headlights, Light on: U = 24 V Headlights, description page 75
high beam rear (E402L-2 & E402R-2) come on D30: Diagnostic menu, see section 8
when the high beams are activated. Control system, group 8.4.11.1 VBFS,
menu 6
31 With reversed operator’s seat: Rear lights front Light on: U = 24 V Tail light, description page 75
(H413L & H413R - red) come on when the D31: Diagnostic menu, see section 8
headlights are activated. Control system, group 8.4.11.1 VBFS,
menu 7
32 With reversed operator’s seat: Brake lights Light on: U = 24 V Brake light, description page 75
front (H410L & H410R) come on when the D32: Diagnostic menu, see section 8
brakes are activated. Control system, group 8.4.11.1 VBFS,
menu 8

Lighting system, component positions

page
–
The purpose of lighting is to increase safety during operation and load

handling. The machine has the following lights:
NOTE
1 2 3 4 5
6, 7
20, 21, 22, 23, 24
8, 9, 10, 11, 12
009729
20 19 18 17 16 14, 15 13
1. Rotating beacon (H428) 13. NO switch, brake lights (S216)

2. Cab roof work lights (E406L-1 E406R-1, E406L-2 & 14.
Frame control unit (D797-2)
E406R-2)
3. Interior lighting (E434-1) 15. Frame control unit (D797-1)
4. Control unit KIT (D790-2) 16. Door NC (normally closed) switch (S266-LE & S266-RI)
5. Multi-function lever (S162) 17. Switch, see section 9 Frame, body, cab and accesso-
ries, group 9.1 Controls and instruments
6. Mast work lights (E404L-1 & E404R-1) 18. Control unit cab (D790-1)
7. Auxiliary mast work lights (E404L-2 & E404R-2) 19.
Relay, cab roof work lights (K3017-1 & K3017-2)
Auxiliary mast work lights (E404L-4 & E404R-4)
8. Rear lights front (H413L & H413R) 20. Headlights, low beam rear (E401L & E401R)
Brake lights front (H410L & H410R) Headlights, high beam rear (E402L-2 & E402R-2)
9. Direction indicators front (H422 & H423) 21. Rear running lights (H416-2 & H417-2)
10. Front running lights (H416-1 & H417-1) 22. Reversing lights (E405L & E405R), white
11. Headlights, low beam (E400L & E400R) 23. Tail lights (H412L & H412R) red
Headlights, high beam (E402L-1 & E402R-1) Brake lights (H411L & H411R)
12. Auxiliary front wing work lights (E404L-2 & E404R-2) 24. Direction indicators rear (H426 & H427)
Auxiliary front wing work lights (E404L-4 & E404R-4)

9 Frame, body, cab and accessories – 9.6.1 Headlights 75
9.6.1 Headlights
Headlights, description
page
–
Headlights are located in the front of the machine to give the operator
enhanced vision when operating in darkness, and to provide surround-
ing traffic and the environment an indication of the machine’s position.
Headlights have high beam and low beam (for meeting other traffic).
Switch between low and high beam with the gear and multi-function le-
ver. The signal goes to the cab control unit (D790-1).
The low and high beam signals can be checked from the diagnostic
menu, section 8 Control system, group 8.4.2.3 LIGHTS, menu 3.
9.6.2 Running light

Running lights, description
page
–
The running lights are located on the right and left-hand sides of the
machine to provide surrounding traffic and the environment an indica-
tion of the machine’s position and direction of travel.
The running lights are controlled by selecting with the headlight switch.
The signal travels to the cab control unit (D790-1).
The lights and their signal can be checked from the diagnostic menu,
section 8 Control system, group 8.4.2.2 LIGHTS, menu 2.
9.6.3 Tail light

Tail light, description
page
–
Tail lights are located in the rear of the machine to provide surrounding
traffic and the environment an indication of the machine’s position, and
a limited enhancement of the view for the operator in darkness.
The tail lights are controlled by selecting with the headlight switch. The
signal travels to the cab control unit (D790-1).
9.6.4 Brake light

Brake light, description
page
–
The brake lights are located in the rear of the machine to provide sur-
rounding traffic and the environment an indication that the machine is
braking and consequently slowing down.
The brake lights are regulated by brake pedal position (via actuated
NC switch). The signal travels to the frame control unit (D797-1), which
supplies power to the brake lights.
see section 8 Control system, group 8.4.2.7 LIGHTS, menu 7 and
8.4.2.8 LIGHTS, menu 8.

76 9 Frame, body, cab and accessories – 9.6.5 Reversing light
9.6.5 Reversing light

Reversing light, description
page
–
The reversing lights are located in the rear of the machine to provide
surrounding traffic and the environment an indication that the machine
is travelling backwards. In addition, this provides the operator en-
hanced view when operating in darkness.
The reversing lights are controlled by the direction of travel (Signal
travels via the CAN bus).
9.6.6 Driving direction indicator

Driving direction indicator, description
page
–
The direction indicators are located on both the front and rear of the
machine to provide surrounding traffic and the environment an indica-
tion that the machine is changing direction, i.e. turning.
The direction indicator is controlled by selecting with the switch (lever)
for direction indicators. The signal travels to the frame control unit
(D797-1).
9.6.7 Flashing hazard lights

Flashing hazard lights, description
page
–
Hazard lights (hazard) are used to warn the surroundings, hazard

lights activate all direction indicators at the same time.
The warning lights are controlled by selecting with the warning light
switch. The signal travels to the cab control unit (D790-1).
Control system, group 8.4.2.4 LIGHTS, menu 4 and 8.4.2.5 LIGHTS,
menu 5.
Machines for the North American market are equipped with flashing
brake lights front and rear during operation.
9.6.8 Rotating beacon

Rotating beacon, description
page
–
A rotating beacon is located high on the machine’s cab. This is used

to provide surrounding traffic and the environment an indication that a
working vehicle is moving and at work. Indication to bystanders to ex-
ercise caution.
The rotating beacon is controlled by selecting with the rotating beacon

9 Frame, body, cab and accessories – 9.6.9 Working lights, mast 77
9.6.9 Working lights, mast

Mast working lights, description
page
–
Work lights on the mast provide enhanced view when load handling in
darkness.
The work lights are controlled by selecting with the mast work light
The mast can be equipped with two auxiliary work lights ( ).
Work lights, changing (product alternative Xenon

page
–
lights)
DANGER
Xenon lights are activated with high voltage. Always
turn off the main electric power before working on xe-
non lights.
Handle the headlights with care since the light is un-

der gas pressure and may explode.
NOTE
The xenon light is filled with different gases and metals. Replaced
xenon headlights should be considered as hazardous waste and
should be deposited for recycling.
9.6.10 Working lights, cab

Working lights, cab, description
page
–
Work lights on the cab provide visibility when handling a load in dark-
ness.
The work lights are controlled by selecting with the switch for cab roof
work lights. The signal travels to the cab control unit (D790-1) which in
turn supplies power to the work lights.

78 9 Frame, body, cab and accessories – 9.6.11 Interior lighting
Work lights, changing (product alternative Xenon

page
–
lights)
See Work lights, changing (product alternative Xenon lights) page 77.
9.6.11 Interior lighting

Interior lighting cab, description
page
–
The interior lighting illuminates the cab when the doors are opened or
when activated with the interior lighting switch.
There is background illumination in all switches, function keys and ro-
tary controls. This is so that the driver will be able to read their func-
tions and settings in darkness. Brightness is controlled by the plus and
minus keys.

9 Frame, body, cab and accessories – 9.7 Signalling system 79
9.7 Signalling system

Signalling system, function description
page
–
NOTE
1 2 3 4
D2 6
D3 17 7
D1
15 D4
16 D17 D7
D6
D15 D18
D13 18
13
14 M
8 19
D14 D790-1 5 D790-2 D795
9
D797-1
D10 D11
10 11 D12
009730
12
Pos Description Signal description Reference

1 The revolving beacon switch (S110) Switch in ON position: U = D1: Diagnostic menu, see section 8 Control
sends a voltage signal to the cab 24 V system, group 8.4.2.6 LIGHTS, menu 6
2 The switch for warning lights (haz- Switch in ON position: U = D2: Diagnostic menu, see section 8 Control
ard) (S109) sends a voltage signal to 24 V system, group 8.4.2.4 LIGHTS, menu 4
the cab control unit (D790-1).
3 The parking brake switch (S107) Switch in ON position: U = D3: Diagnostic menu, see section 8 Control
sends a voltage signal to the cab 24 V system, group 8.4.5.4 HYD, menu 4
4 The horn switch (S149-3) sends a Switch in ON position: U = D4: Diagnostic menu, see section 8 Control
voltage signal to the cab control unit 24 V system, group 8.4.3.5 CAB, menu 5
(D790-1).
5 The cab control unit (D790-1) trans- Checked by control sys- Section 11 Common electrics, group 11.5.3.1
mits activation messages on the tem, error shown with er- Cab control unit (D790-1)
CAN bus ror code.
6 The multi-function lever (S162) Signal button pressed in: Gear and multi-function lever, description
sends a voltage signal to the KIT US162/H = 24 V page 12
control unit (D790-2). D6: Diagnostic menu, see section 8 Control
system, group 8.4.3.5 CAB, menu 5

80 9 Frame, body, cab and accessories – 9.7 Signalling system

7 The direction indicator lever (S161) Left: US161/6 = 24 V D7: Diagnostic menu, see section 8 Control
sends a voltage signal to the KIT system, group 8.4.2.4 LIGHTS, menu 4
Right: US161/1 = 24 V
8 The KIT control unit (D790-2) trans- Checked by control sys- Section 11 Common electrics, group 11.5.3.11
mits activation messages on the tem, error shown with er- KIT control unit (D790-2)
CAN bus. ror code.
9 The frame control unit (D797-1) sup- Checked by control sys- Section 11 Common electrics, group 11.5.3.2
plies voltage to the machine lights tem, error shown with er- Frame control unit (D797-1)
and buzzers. ror code.
10 Direction indicators (H422,H423, Light on: U = 24 V Driving direction indicator, description page 76
H426 & H427) come on when the D10: Diagnostic menu, see section 8 Control
flashing hazard lights are activated. system, group 8.4.2.5 LIGHTS, menu 5
11 The reversing lights (E405L & Light on: U = 24 V Reversing light, description page 76
E405R) come on when reverse gear D11: Diagnostic menu, see section 8 Control
is selected. system, group 8.4.2.8 LIGHTS, menu 8
12 Back-up alarm (H965) is activated Reverse gear engaged: U Reversing alarm, description page 82
when reverse gear is selected. = 24 V D12: Diagnostic menu, see section 8 Control
13 Horn (H850) sounds when the horn Horn active: U = 24 V Horn, description page 81
is activated. D13: Diagnostic menu, see section 8 Control
system, group 8.4.3.5 CAB, menu 5
14 Rotating beacon (H428) is lit when Light on: U = 24 V Rotating beacon, description page 76
hazard lights are activated. D14: Diagnostic menu, see section 8 Control
15 Relay loud horn (K3016) is activated UK3016/30 = 24 V Horn, description page 81

when horn is activated. D15: Diagnostic menu, see section 8 Control
UK3016/85 = 0 V
Horn activated:
UK3016/86 = 24 V
UK3016/87 = 24 V
16 Loud horn (H850-1) sounds when Horn active: U = 24 V Horn, description page 81
the horn is activated.
17 The operator-in-seat NO switch Operator in seat: U = 24 V Sensor operator in seat, description page 28
(S230) sends a voltage signal to the D17: Diagnostic menu, see section 8 Control
cab control unit (D790-1) when there system, group 8.4.3.6 CAB, menu 6
is a load on the operator’s seat.
18 In the event of warnings, the cab Checked by control sys- D18: Diagnostic menu, see section 8 Control
buzzer (H853) is supplied voltage by tem, error shown with er- system, group 8.4.3.6 CAB, menu 6
the KIT control unit (D790-2) to draw ror code.
the operator’s attention to the warn-
ing message.

9 Frame, body, cab and accessories – 9.7.1 Horn 81

19 In the event of warnings, the KID A clicking sound is audible Section 11 Common electrics, group 11.5.3.12
control unit (D795) activates the when then termination re- KID control unit (D795)
warning light to draw the operator’s sistor is activated.
attention to the warning message.
NOTE
On machines prepared for or equipped with a separate top lift attachment, an acoustic signal may also be given with
the button open twistlock (S1002) on the panel for hydraulic functions or open twistlock on the joystick provided that the
"open twistlocks upon alignment" function is not active.
Signalling system, component position

page
–
The machine has the following signalling systems:
13, 14 1 2 3 4
007109
11, 12 10 9 8 7 6
1. Rotating beacon (H428) 8. Switch, see section 9 Frame, body, cab and accesso-
ries, group 9.1 Controls and instruments
2. Control unit KIT (D790-2) 9. Horn (H850)
3. Buzzer cab (H853) 10. Make-contact operator in seat (S230)
4. Control unit KID (D795) 11. Control unit cab (D790-1)
5. Direction indicators front (H422 & H423)
12. Relay loud horn (K3016)
6. Frame control unit (D797-1) 13. Direction indicators rear (H426 & H427)
14. Back-up alarm (H965)
7. Loud horn (H850-1)
9.7.1 Horn
Horn, description
page
–
The horn is electromagnetic. Air horn can be selected ( ).

The horn is activated from the gear and multi-function lever or from the
horn switch ( ). The horn is located under the cab (the compressed
air horn is located on the cab’s front edge).
001247
Control system, group 8.4.3.5 CAB, menu 5..

82 9 Frame, body, cab and accessories – 9.7.2 Flashing hazard lights
9.7.2 Flashing hazard lights

Flashing hazard lights, description
page
–
See Flashing hazard lights, description page 76.
9.7.3 Rotating beacon

Rotating beacon, description
page
–
See Rotating beacon, description page 76.
9.7.4 Warning parking brake

Warning parking brake, description
page
–
If the operator leaves the machine without applying the parking brake,
a buzzer sounds to alert the operator, i.e. to ensure the operator ap-
plies the parking brake.
A sensor in the operator’s seat (see Sensor operator in seat, descrip-
tion page 28) indicates to the control system if the operator leaves the
seat.
The buzzer is located in the steering wheel panel.
Control system, group 8.4.3.6 CAB, menu 6..
9.7.5 Reversing alarm

Reversing alarm, description
page
–
When reverse is selected, a warning sound and the back-up lights are
activated. This is to give others in traffic an indication that the machine
is reversing. Indication to bystanders to take caution.
Control system, group 8.4.2.8 LIGHTS, menu 8.

9 Frame, body, cab and accessories – 9.8 Entertainment and communication 83
9.8 Entertainment and

communication
Entertainment and communication, general
page
–
The machine is prepped with a connector for customer accessories,

see section 11 Common electrics, group 11.5.2.1 Electrical distribu-
tion box, cab.
Entertainment and communication, repair

page
–
Repairs should be left to authorised personnel.

84 9 Frame, body, cab and accessories – 9.9 Glass/windows/mirrors
9.9 Glass/windows/mirrors
Glass/windows/mirrors, description
page
–
The windows are designed to both enclose the cab and provide the op-
C erator with a good view.
The windows on the Spirit Delta cab are made of tinted hardened
D
glass, except the roof window which is made of polycarbonate plastic.
As an option, the cab can be equipped with windows of laminated

glass.
The rearview mirrors are of the convex mirror type. There is an interior
rearview mirror on all machines.
001512
A E B
A. Side windows
B. Windshield (front window)
C. Roof window
D. Rear window
E. Windshield (Side window front)
Silicone adhesive, handling advice

page
–
The window panes are secured with key adhesive and silicone adhe-
sive.
NOTE
The purpose of this instruction is to describe how silicone adhe-
sive 923854.0100 should be handled in connection with replace-
ment of the windscreen and roof window on the Spirit Delta cab.
• Silicone adhesive 923854.0100 is a quick-hardening, two-
component silicone adhesive that can withstand tempera-
tures between -50 °C and +200 °C. The hardening properties
of the adhesive are extremely dependent on the ambient
temperature. An increase of 10 °C cuts hardening time in
half.
Silicone adhesive 923854.0100 is mixed at a ratio of 1:10 in
a static mixer. Change mixer after every interruption that
lasts more than 5 minutes. The short setting time means that
work has to be planned carefully to avoid undesired harden-
ing.
Fixing time:
10-20 minutes at 20 °C
approx. 5 minutes at 60 °C

9 Frame, body, cab and accessories – 9.9.1 Windscreen 85
Hardening time:
approx. 24 hours at 20 °C
approx. 1 hour at 60 °C
Full strength is obtained after 7 days.
• In warm climates, it is advantageous to cool the container to
increase hardening time. The silicone adhesive should not
be used at temperatures above +75 °C.
• In cold climates, the hardening time can be shortened by
covering the joints so that cooling is prevented. The window
pane can be warmed with defroster or cab heater.
• The recommended storage temperature is between -30 °C
and +20 °C. Storage in a refrigerator or a colder environment
is recommended.
9.9.1 Windscreen
Windscreen, description
page
–
The windshield consists of the front window and side windows. The
windshield is attached to the cab with a key strip and is glued to the
roof window with silicone adhesive. Front and side windows are joined
with silicone adhesive to give good allround visibility from the opera-
tor’s station.
For location, see Glass/windows/mirrors, description page 84.
Windscreen, replacement
page
–
NOTE
Read the handling advice for silicone adhesive before starting
work. See Silicone adhesive, handling advice page 84.

2 Remove the key strip.
3 Remove the broken window pane and check that no glass or oth-
er particles remain in the window pane’s groove on the strip. Cut
apart silicone joints with a sharp tool.
NOTE
Make sure that no silicone adhesive remains between the
window pane and the strip by the window pane’s lower front
edge.
Figure 1: Removing key strip

86 9 Frame, body, cab and accessories – 9.9.1 Windscreen
If the roof window is to be changed, then all bolts must be

removed before the silicone adhesive is cut away.
CAUTION
Acetone may not come into contact with a roof win-
dow made of polycarbonate plastic. Acetone has a
chemical effect on the polycarbonate plastic which
reduces the roof window’s strength.
4 Clean all surfaces thoroughly. Remove old remains of silicone

with a razor blade or similar.
5 Fit masking tape on the inside and outside of the window panes
by the surfaces that are to be glued.
6 When the windshield or a side window is to be changed, then the
1 2 3
window panes must be adjusted so that the upper edge on the
side window has the same height as the top edge of the roof (see
figure 2) and so that the distance between windshield and side
window is as shown in figure 3.
Use spacers against the roof member to ensure that the distanc-
es are obtained.
1
006268
1,0
1
Figure 2: Adjusting side window - cab window
1. Side window
2. Rubber strip
3. Cab frame / door opening
006269
1,0
Figure 3: Adjusting side window - windshield

1. Masking tape
7 Install the key strip around the whole window pane.
8 Apply silicone adhesive 923854.0100 around the window panes.
Make the new joint wider than the old one to create a good seam.
The silicone should be applied from the outside of the joints, to
give a full and smooth joint.
NOTE
There must be silicone between the window panes, to avoid
contact between the window panes.

9 Frame, body, cab and accessories – 9.9.2 Side window 87
9 Remove excess silicone adhesive from the outer vertical corners

with a tool made of cardboard as shown in figure 4. Smooth out
the joints on the inside with a finger, wet with water or soapy
water.
10 Apply silicone adhesive 923854.0100 between the strip and win-
dow pane at the bottom edge of the front corners, so-called top
sealing.
11 If the roof window is to be replaced, apply silicone adhesive
923854.0100 by the cab frame (where it was glued earlier).
12 Lay the roof window into place and check that there is a uniform
distance of one or several millimetres along the window pane’s
edges and by the protection over the frame’s sides. Then tighten
the corner bolts for the window pane.
006272
13 Apply silicone adhesive 923854.0100 by the edges and smooth
out the joints with a finger, wet with water or soapy water.
Figure 4: Tool template for silicone joint, scale 1:1

IMPORTANT
Mark the window panes with "New adhesive. Do not
touch.".
14 Remove the masking tape immediately after applying adhesive to

avoid edge formation. Hardening time is dependent on ambient
temperature, plan the change so that downtime is minimized.
9.9.2 Side window

Side window, description
page
–
The side windows are secured in the cab and doors with key strips.
For further details, see Glass/windows/mirrors, description page 84.
Side window, replacement

page
–
NOTE
The method describes a general procedure.

88 9 Frame, body, cab and accessories – 9.9.2 Side window
2 Use special tools to detach the wedge strip.
3 Remove the wedge strip which runs around the whole window.
4 Carefully remove any glass remains from the rubber strip.
5 Fit the new window, securing it at the bottom edge.

9 Frame, body, cab and accessories – 9.9.2 Side window 89
6 Spray soap solution on the window and rubber strip to facilitate

fitting.
7 Thread the rubber strip around the whole window; use special
tools.
8 Secure the wedge strip with a special tool.

9 Pull the wedge strip around the whole window.

90 9 Frame, body, cab and accessories – 9.9.2 Side window
10 Cut off the wedge strip approx. 2 cm too long.

11 Fit the other end of the wedge strip edge to edge.
12 Adjust the wedge strip so that the correct fit is obtained.

9 Frame, body, cab and accessories – 9.9.3 Roof window 91
9.9.3 Roof window

Roof window, description
page
–
The roof window is made of polycarbonate plastic, which is a safety

feature for the operator, intended to protect the operator from falling
objects. The polycarbonate plastic is elastic.
Safety is maintained within a temperature interval of 120 °C to -45 °C
(becomes brittle at -110 °C, glass conversion temperature 145 °C).
The roof window has a patented surface layer that increases its resist-
ance to wear, UV light and chemicals.
The roof window is joined with the windshield. Joints between the win-
dow panes and between roof window and cab are sealed with silicone
adhesive. Lay a new seal of silicone adhesive when replacing.
For location, see Glass/windows/mirrors, description page 84.
WARNING
The strength of the roof window may be significantly
reduced in case of exposure to substances contain-
ing: aromatic hydrocarbons, ketones, esters and
chlorinated hydrocarbons.
Check the roof window’s surface at regular intervals,

and only clean with washer fluid or mild cleaning
agents. Rinse with lukewarm water. Replace the roof
window if it is damaged, cracked, or scratched!
Roof window, replacement

page
–
See Windscreen, replacement page 85 for the general procedure.

The roof window is combined with the windscreen. The joint is sealed
with silicone. Add a new silicone seal when replacing.
9.9.4 Rear window

Rear window, description
page
–
The rear window is attached to the cab with a key strip.
On machines with hydraulic sliding cab or hydraulic cab lift and

lower, the rear window can be opened to provide an emergency exit.
For further details, see Glass/windows/mirrors, description page 84.
Rear window, replacement

page
–
See Side window, replacement page 87 for the general procedure.

92 9 Frame, body, cab and accessories – 9.9.5 Rearview mirror
9.9.5 Rearview mirror

Rearview mirror, description
page
–
The cab has one rearview mirror located in the cab and external rear-
view mirrors out on the machine. The rearview mirrors give the opera-
tor a view around the machine.
1. provides a view of the area in front of the machine
9a
2. provides a view of the area at the side of the machine
3. provides a view of the area behind the machine
9a 9b
9b 9c
007328
The illustration depicts DCF 300-330LB
2
2
1 1
3
3
2
009733
2
009732
DCF 370-500
DCF 280-330HB

9 Frame, body, cab and accessories – 9.9.6 Reversing camera 93
9.9.6 Reversing camera

Reversing camera, description
page
–
The reversing camera is located at the rear edge of the horizontal

counterbalance weight, furthest back on the machine. It is designed to
provide improved vision when reversing. The reversing camera is wa-
tertight and has a microphone and infrared lighting for night vision. In
addition, the camera is equipped with automatic heating which is acti-
vated at ambient temperatures below +10 °C.
1
2 The reversing camera sends colour images and audio to the monitor
in the cab; see Monitor, reversing camera, description page 93.
1 007425
3
1. IR-diodes
2. Camera
3. Microphone
9.9.7 Monitor, reversing camera

Monitor, reversing camera, description
page
–
The monitor shows picture and sound from the back-up camera. The
CA.SE
L
1 picture is shown in colour and light intensity is automatically adjusted
according to light conditions in the cab. The monitor can handle sig-
MENU
2 nals from two different cameras.

VOL
The monitor is mounted on a hinged bracket to the left in front of the
3 door in the cab.
BRI
4
007416
5
1. Choice of camera
2. Menu
3. Light intensity
4. Volume setting
5. On and off

94 9 Frame, body, cab and accessories – 9.10 Cab structure and suspension
9.10 Cab structure and

suspension
Cab structure and suspension, description
page
–
The cab is mounted in a cab undercarriage via strong rubber insulators

located on the underside of the cab. This minimises vibrations from the
frame to the cab. There is an insulator at four points - one at each cor-
1 ner. Each insulator mounting has one rubber bushing and one bolt.
3
003206
4
Cab Spirit Delta
1. Cab frame
2. Door
3. Cab suspension
4. Cab undercarriage
9.10.1 Cab frame

Cab frame, description
page
–
The cab frame is made of high-strength steel sheet profiles. The cab
is dimensioned to handle impacts and, to some degree, dropped
loads. The frame must not be modified!
002210
Cab Spirit Delta

9 Frame, body, cab and accessories – 9.10.2 Doors 95
9.10.2 Doors
Doors, description
page
–
The cab has two doors - the left is the operator’s door and the right is
the emergency exit. The door has:
• rail
• handle
• key lock
• openable window (passenger door )

Switches in the doors’ locks sense if the door is open. The switch is
used to light the interior lighting and warn of an open door.
Control system, group 8.4.2.9 LIGHTS, menu 9 or 8.4.11.5 MOVE-
CAB, menu 1.
9.10.3 Cab undercarriage

Cab substructure, description
page
–
The cab is mounted on a cab undercarriage via strong rubber insula-

tors located on the underside of the cab. This is to minimize vibrations
from the frame to the cab.
The cab undercarriage is fitted on the machine’s chassis (frame) via a
mounting. The chassis mounting depends on whether the machine is
equipped with hydraulic cab tilt.

96 9 Frame, body, cab and accessories – 9.10.4 Hydraulic sliding cab
9.10.4 Hydraulic sliding cab

Hydraulic sliding cab, description
page
–
A hydraulic cylinder slides or pulls the cab laterally.

1 2
3 4 5 007160
1. Ball bearing-mounted wheel

2. Rails
3. Sled
4. Isolators
5. Hydraulic cylinder

9 Frame, body, cab and accessories – 9.10.4 Hydraulic sliding cab 97

Emergency stop switch Not activated Section 11 Common electrics, group 11.5.1.4 Emergency stop switch
voltage
Parking brake Released -
Doors Closed -
Speed < 5 km/h -
D5
5
6
D790-1
D797-1 D797-2
D7
3 9 7
D9 D9
10 8
2 A 4
T H B1
P C
P
P2 13
A1
T
P1 B1
T A1
12
11
10
EF
P
1 1 T
010069

1 The hydraulic oil pump pumps oil from See pressure plate on left Section 10 Common hydraulics, group
2 The pressure reducer reduces the pres- P = 3.5 MPa Section 7 Load handling , group 7.2.3 Pres-
sure from one of the hydraulic pumps to sure reducer
servo pressure.
3 The accumulator stores servo pressure. See pressure plate on left Section 10 Common hydraulics, group
The non-return valve in the pressure re- frame beam. 10.3.2 Accumulator

98 9 Frame, body, cab and accessories – 9.10.4.1 Cab sled, description

4 The servo filter cleans the oil upstream - Section 7 Load handling, group 7.2.2 Servo
of the load handling control valve. filter
5 The switch (S1010) sends a voltage sig- U = 0.5-4.5 V DC Controls and instruments, overview page 5
nal to the cab control unit (D790-1). D5: Diagnostic menu, see section 8 Control
system , group 8.4.11.5.1 ENGINE, menu 1
6 The cab control unit (D790-1) sends cab Checked by the control Section 11 Common electrics, group
slide right/left to the control units (D797- system; error shown with 11.5.3.1 Cab control unit (D790-1)
1) and (D797-2) via the CAN bus. error code.
7 The frame control (D797-2) directs cur- Checked by the control Section 11 Common electrics, group
rent to the solenoid valve for the system; error shown with 11.5.3.3 Frame control unit (D797-2)
changeover valve for cab shift (Y6080). error code. D7: Diagnostic menu, see section 8 Control
system, group 8.4.11.5.5 ENGINE, menu 5
8 The solenoid valve for the changeover - Section 7 Load handling, group 7.4.5 Load
valve for cab shift (Y6080) directs servo handling control valve
pressure to the slide for the cab shift
changeover valve.
9 The frame control unit (D797-1) directs Checked by the control Section 11 Common electrics, group
current to the side shift right solenoid system; error shown with 11.5.3.2 Frame control unit (D797-1)
valve (Y6020) or side shift left solenoid error code. D9: Diagnostic menu, see section 8 Control
valve (Y6021). system, group 8.4.11.5.6 ENGINE, menu 6
system, group 8.4.11.5.7 ENGINE, menu 7
10 The solenoid valve for side shift right - Section 7 Load handling, group 7.4.5 Load
(Y6020) or the solenoid valve for side handling control valve
shift left (Y6021) directs servo pressure
to the side shift spool in the load han-
dling control valve.
11 The control valve spool changes posi- - Section 7 Load handling , group 7.4.5 Load
tion and pressurises the side shift valve handling control valve
block.
12 The side shift changeover valve block is - Changeover valve, sliding cab, description
pressurised. page 99
13 The hydraulic cylinder is pressurised - Section 10 Common hydraulics, group

and the cab is shifted. 10.7.1 Hydraulic cylinders

draulics, Hydraulic diagram of basic machine.
9.10.4.1 Cab sled, description

Cab sled, description
page
–
The cab runs on a sled with ball bearing-mounted wheels. The sled is
screwed on isolators to the cab undercarriage. The sled’s ball bearing-
mounted wheels run in rails that are screwed to the machine frame.
The sled can be moved laterally via a hydraulic cylinder.

9 Frame, body, cab and accessories – 9.10.4.2 Hydraulic pump 99
9.10.4.2 Hydraulic pump

Hydraulic pump, description
page
–
2 The hydraulic sliding cab is supplied pressure from a hydraulic pump;

see section 10 Common hydraulics, group 10.4.3 Vane pump with
fixed displacement.
1
007216
1. Hydraulic pump for cooling, filtering and sliding cab.
9.10.4.3 Changeover valve, sliding cab

Changeover valve, sliding cab, description
page
–
The hydraulic sliding cab is controlled by a section in the load handling

control valve (side shift). A changeover valve is used to switch the
pressure from the slide function to pressure for the sliding cab hydrau-
lic cylinder.
The changeover valve for sliding cab is regulated by a servo valve. An
electrically operated pressure reducing valve (servo valve) converts
electric current to a low hydraulic pressure, so-called servo pressure.
The servo pressure actuates the control spool in the control valve,
thereby regulating main flow.
007168
1 2
Side shift spool
1. Load handling control valve (side shift)
2. Changeover valve, sliding cab The valve spool regulates whether the function side shift of forks or
sliding cab is active.
The valve spool is regulated by the servo valve for sliding cab.
Servo valve, sliding cab

The servo valve for side shift left directs pressure to the side shift
spool, causing it to open and pressurise the sliding cab cylinder.
The sliding cab servo valve is regulated electrically via the solenoid
valve for sliding cab (Y6080), which is activated by the frame control
unit (D797-2). The servo valve directs servo pressure out to the side
shift slide.

100 9 Frame, body, cab and accessories – 9.10.4.4 Accumulator servo circuit
9.10.4.4 Accumulator servo circuit

page
–
See section 7 Load handling, group 7.2.4 Accumulator, servo circuit.
9.10.5 Cab tipping

Cab tipping, description
page
–
The Spirit Delta cab for DCF 280-330 can be tipped up to an angle, so
that it tips over its equilibrium position. The cab is suspended on the
left side with hinges and is tipped with the help of a hydraulic cylinder.
Hydraulic pressure is generated with a hand-driven hydraulic pump,
which has an integrated valve that controls whether the cab is tipped
up or down.
The right side of the cab houses two cab suspensions with locking de-
vices that secure the cab to the frame. The locking devices are easily
released when the cab must be tipped.
Electric cab tipping is available as an option.

9 Frame, body, cab and accessories – 9.11 Cab interior 101
9.11 Cab interior

9.11.1 Instrument and control panels
Dashboard panel, description
page
–
The dashboard panel is secured to the steering column and contains

warning and indicator lamps, display (KID), function keys (KIT) and
switches.
Left-hand dashboard panel, description

page
–
Left instrument panel is located in the left corner of the cab. It contains
rotary controls, switches, and ventilation.
Panel for load handling functions, description

page
–
The panel, which is mounted on the operator’s seat, houses switches

and controls for load handling functions and a emergency stop switch
to interrupt load handling functions in progress.
On machines equipped with a control lever, it is located next to the
panel .
Dashboard panel, replacement

page
–

2 Remove the steering wheel centre cover.
3 Remove the nut and the steering wheel.

102 9 Frame, body, cab and accessories – 9.11.2 Interior details, plastic
4 Remove the bolts on the underside of the dashboard panel.
5 Remove the bolts on the top of the dashboard panel.
6 Unplug the connector from the multi-function levers, ignition

switch, KIT control unit (D790-2) and KID control unit (D795).
7 Transfer the components to the new steering wheel cover.
9.11.2 Interior details, plastic

Interior plastic parts, description
page
–
The interior of the cab consists of recyclable material.
9.11.3 Interior details, textile

Interior textile parts, description
page
–
The interior of the cab consists of recyclable material.

9 Frame, body, cab and accessories – 9.11.4 Floor covering 103
9.11.4 Floor covering

Floor covering, description
page
–
The floor covering is a wear-resistant and recyclable material.
9.11.5 Insulation
Insulation, description
page
–
The cab insulation consists of recyclable material.
9.11.6 Sun blinds

Sun blinds, description
page
–
Sun blinds can be chosen for the front window (windscreen) and the
roof window.
1. Sun visor, front window: Can be raised and lowered using a cord
on the right-hand side. Stops in selected position.
2. Sun visor, roof window: Extends forward to fasten in two hooks in
the front edge of the window.
9.11.7 Terminal console

Terminal console, description
page
–
The function of terminal desk is to provide a work surface for a com-

puter/terminal. It is located to the right of the steering wheel, easily ac-
cessible for the operator.
008227
9.11.8 Reading-lamp
Reading lamp, description
page
–
The reading lamp is fitted on a jointed bracket to the right in front of the
door in the cab.

104 9 Frame, body, cab and accessories – 9.11.9 Writing desk
9.11.9 Writing desk

Writing desk, description
page
–
The writing table with reading light is located on a flexible attachment

to the right in front of the door in the cab. That is where work orders,
etc. can be fastened.
008228

9 Frame, body, cab and accessories – 9.12 Frame 105
9.12 Frame
Frame, description
page
–
The frame is a modular construction and consists of front section, rear

section and a beam pair. This construction provides advantages in
terms of rigidity and strength.
There are mounting points in the frame for engine, gearbox, drive axle,
steering axle, fuel and hydraulic tanks, cab, mast and body parts.
The space in the rear section of the frame is used for counterweights,
the number of which is adapted to the machine in question. The coun-
terweights are designed to allow as good a view rearwards as possi-
ble.
The front wings are bolted into the frame (which has advantages when
delivering the machine).
4 007949
1. Frame’s rear part with counterweights

2. Engine compartment with mountings for engine and transmission
3. Frame’s front part with drive axle mounting
4. Mounting for front wing
5. Cab mounting (4 points)
6. Steering axle mounting

106 9 Frame, body, cab and accessories – 9.13 Body
9.13 Body
Body, description
page
–
The body’s components comprise:
007950
1. Counterweight
2. Hood engine compartment
3. Fenders
9.13.1 Fenders
Fenders, description
page
–
There are fenders over the wheels to protect from dirt thrown up by the
wheels during operation. The design of the counterweight (see Coun-
terweight, description page 107) acts as a mudguard for the rear
wheels.
The fenders can be equipped with extra mudguards when the ma-
chine’s work environment requires such ( ).

9 Frame, body, cab and accessories – 9.13.2 Hood engine compartment 107
9.13.2 Hood engine compartment

Hood engine compartment, description
page
–
The engine compartment of the machine is protected by two hoods

with safety catches - one on each side of the engine.
The machine space for the transmission and driveline/axle is protect-
ed by tread plates. The tread plates are divided into five sections and
are secured with retaining bolts. The tread plates are designed to be
walked on and are ribbed to provide sure footing.
9.13.3 Footstep and rail

Steps and rails, description
page
–
The cab area has footsteps for easy access. There is a rail by the cab
area.
9.13.4 Counterweights
Counterweight, description
page
–
The machine has counterweights to balance the machine’s lift capac-

ity and may therefore vary in quantity and weight.
The counterweights are located at the very back of the frame for max-
imal leverage.
The machine has counterweights in the following places:
• Under the steering axle
• Furthest back on the machine there are vertical counterweights
secured in the rear edge of the frame; the outer has a towing eye.
Between the outer counterweight and the frame, there are smaller
counterweights whose dimensions and quantity are adapted to
balance the machine’s lifting capacity.
• Upper horizontal counterweight.
Under the horizontal counterweight, there are smaller counter-
weights whose dimensions and quantity are adapted to balance
the machine’s lifting capacity.
DANGER
The counterweights are factory fitted and are adapted
according to the machine's properties.
The machine's operating characteristics are changed!
Never change the quantity of counterweights.

108 9 Frame, body, cab and accessories – 9.14 Central lubrication
9.14 Central lubrication

Central lubrication, checking
page
–
1 Check that no grease has been forced out through the safety
valve (position 2).
If grease has been forced out through the safety valve it means
that there is a stop in the system. Determine which line is clogged
by feeling the connections at the distribution blocks. A clogged
hose remains pressurised and the connection becomes hard.
NOTE
If several distribution blocks are connected in series, a
clogged line will be pressurised all the way to the first distri-
bution block.
2 Turn the start key to position I.
3 Operate the pump manually and check that the indicator pin
moves in and out on the distribution blocks.
To operate the pump, loosen the cover and press in the switch for
manual operation (position 5).
If the indicator pins do not move even when the pump is running,
Overview of central lubrication pump unit and distribu-
troubleshoot the pump unit.
tion box. Example image.
1. Grease nipple, filling of lubricating grease
2. Safety valve
NOTE
3. Grease nipple, manual system lubrication The system can be lubricated manually through the grease
4. Indicator pin nipple on the distribution block (position 3).
5. Switch, manual operation 4 Fill grease in the pump unit through the filler nipple, see section
F Technical data.

9 Frame, body, cab and accessories – 9.14 Central lubrication 109
Central lubrication, adjusting lubrication times

page
–
The central lubrication’s pause and run-time must be set after replace-
ment, the setting is unique to each machine, depending on the ma-
chine’s equipment. At replacement, the new pump unit should be set
in the same way as the old.
If the machine is not greased correctly, pause and run-time can be ad-
justed. Primarily, run-time should be adjusted so that all grease points
on the machine are greased every time. If large amounts of grease are
pressed out at all grease points, pause-time can be increased.
NOTE
Adjust only one step each time. Small adjustments make a big
difference.
Test or extra greasing

Central lubrication can be operated manually by holding in the button
for manual operation (position 3) for 2 seconds. This starts an extra lu-
brication cycle.
Pause-time
Pause-time is the length of the interval between greasings. The inter-
Example figure
val is adjusted in whole hours between 1 and 15 hours. Pause-time is
1. Setting pause-time (red)
adjusted with the red handle (position 1)
2. Setting run-time (blue)
3. Manual operation of pump
Switch position 1 2 3 4 5 6 7 8 9 A B C D E F
Pause-time [hours] 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Run-time
Run-time is how long the pump is activated every time. Run-time can
be adjusted between 2 and 30 minutes. Pause-time is adjusted with
the blue handle (position 2).
Switch position 1 2 3 4 5 6 7 8 9 A B C D E F
Run-time [minutes] 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30

110 9 Frame, body, cab and accessories – 9.14.1 Pump unit
9.14.1 Pump unit

Pump unit, description
page
–
The pump unit consists of containers with stirrer, pump housing with
built-in motor, timer, pump element, filler nipple, and safety valve.
The central lubrication works with lubrication cycles (pause and run-
ning time as well as read-in time). In the pump there is a circuit board
with a timer with which one can set the pump motor’s run and pause
time.
When the central lubrication works, it greases the grease points one
at a time in series. If a stop should occur in a grease point, the pres-
sure will increase and the safety valve will release grease and also the
following grease points will not be greased.
NOTE
The safety valve will press out grease if a grease point cannot be
greased. If a grease point is not greased, none of the following
grease points will be greased Therefore, it is very important to
check the safety valve.
Example figure components central lubrication

1. Pump unit
2. Safety valve

9 Frame, body, cab and accessories – 9.14.2 Distribution block 111
9.14.2 Distribution block

Distribution block, description
page
–
The distribution blocks distribute grease from the pump unit to grease
points or on to other distribution blocks. The number of distribution
blocks can vary depending on how may (and which) grease points
have been selected.
The distribution blocks consist of pistons that meter out grease to each
grease point. The pistons are driven by the grease and do not have
springs and gaskets. It is the grease that drives the pistons inside the
distributor. The shape of the pistons and channels in the distribution
block enable the pistons to move in a predetermined way. Each piston
must have completed its motion before the next piston can move. The
pistons are dependent on each other. It is technically impossible to
skip any connected grease point. If a grease point cannot be greased,
the whole system is blocked and grease is pressed out through the
safety valve.
The system’s first distribution block (i.e. the block closest to the pump)
has an indicator pin. If the pin moves forward and backward (in time
with the piston movements), this indicates that grease is pumped
Example figure components central lubrication through the system. If a distribution block is unable to supply grease
1. Pump unit to any of its lubrication points, the pin stops and accordingly the entire
2. Safety valve system.
If there is clogging in the system, that line will be pressurized, from the
pump to the stop, through all the distribution blocks on the way. This
makes it easy to find a block in the system. By feeling the distribution
blocks’ connections and feeling which connection is stiff, the blockage
can be traced. Keep in mind that several distribution blocks may be
connected in series.
9.14.3 Lines
Lines, description
page
–
Central lubrication works under very high pressure, only use lines that
meet the following specifications.
Main hose
Diameter 8.4 mm
Explosion pressure min. 60.0 MPa

112 9 Frame, body, cab and accessories – 9.15 Paint/coatings
9.15 Paint/coatings
Paint/coatings, description
page
–
The machine is painted using a single-layer paint, thickness 120 my.

For colour code (RAL) of machine in question, see machine card.
Please contact Kalmar Industries for information about other surface
treatment and material colours.

10 Common hydraulics 1
Table of Contents 10 Common hydraulics

mm mm mm mm mm mm
10 Common hydraulics....................................................................................... 3
10.2 Safety valves .............................................................................................. 3
10.2.1 Accumulator drain valve ........................................................................ 3
10.2.3 Pipes and hoses .................................................................................... 3
10.3 Tanks and accumulators ............................................................................ 4
10.3.1 Tank ....................................................................................................... 4
10.3.2 Pipes and hoses .................................................................................... 4
10.4 Pumps ........................................................................................................ 5
10.4.3 Vane pump with fixed displacement ...................................................... 5
10.4.4 Pipes and hoses .................................................................................... 8
10.5 Hoses, pipes and valves ............................................................................ 9
10.5.1 Pipes and hoses .................................................................................... 9
10.5.2 Priority valve ........................................................................................ 10
10.5.3 Shuttle valve ........................................................................................ 10
10.5.5 Proportional valves .............................................................................. 11
10.6 Temperature control, cleaning and hydraulic oil ....................................... 12
10.6.1 Tank heater .......................................................................................... 14
10.6.2 Cooler hydraulic oil .............................................................................. 15
10.6.3 Cooling fan ........................................................................................... 17
10.6.4 Sensor hydraulic oil temperature ......................................................... 17
10.6.5 Radiator bypass valve ......................................................................... 19
10.6.6 Breather filter hydraulic oil tank ........................................................... 20
10.6.7 Oil filter ................................................................................................. 21
10.6.8 Hydraulic oil ......................................................................................... 22
10.6.9 Hydraulic oil fine-filter .......................................................................... 23
10.6.10 Pipes and hoses .................................................................................. 24
10.7 Auxiliaries ................................................................................................. 25
10.7.1 Hydraulic cylinders ............................................................................... 25

2 10 Common hydraulics

10 Common hydraulics – 10 Common hydraulics 3
mm mm mm mm mm mm
10.2 Safety valves

10.2.1 Accumulator drain valve
Accumulator drain valve, description
page
–
The accumulator drain valve is located on the accumulator charging

valve. See section 4 Brakes, group 4.3.3 Accumulator charging valve.
007210
1. Accumulator drain valve

Pipes and hoses, general
page
–
See Pipes and hoses, general page 9.

4 10 Common hydraulics – 10.3 Tanks and accumulators
10.3 Tanks and accumulators

10.3.1 Tank
Tank, description
page
–
The hydraulic oil tank forms part of the side panel on the right-hand
1 2 1 2
3 side of the machine. The oil filters for the working hydraulics sits inside
the tank. These are accessible through hatches on top of the tank.
4 Hydraulic oil is filled directly into the tank through the filler caps on the
filter manhole covers. For oil capacity and grade, see section F Tech-
nical data. The entire filter unit can be removed to facilitate access for
cleaning. There are drain plugs at the bottom of the tank.
5
The tank has filtered venting which allows changes in the tank volume
due to usage and temperature variations.
The oil level is checked on the level glass on the tank’s side when all
hydraulic cylinders are in the bottom position.
007211
1. Cover for hydraulic oil filer

2. Hydraulic oil filler orifice
3. Breather filter, hydraulic oil tank
4. Sight glass, hydraulic oil
5. Drain plugs, hydraulic oil

page
–

10 Common hydraulics – 10.4 Pumps 5
10.4 Pumps
10.4.3 Vane pump with fixed displacement
Vane pump with fixed displacement, description
page
–
There are three vane pumps with fixed displacement.

The pumps have the following functions:
2
1. Hydraulic oil pump that feeds the brake system’s brake and cool-
ing circuits via an accumulator charging valve; see section 4
1 Brakes, group 4.3.1 Brake fluid pump and 4.8 Temperature con-
trol, cleaning and brake fluid.
2. Hydraulic oil pump that feeds load handling.
3
3. Hydraulic oil pump that feeds steering and load handling. The pri-
ority valve ensures that there is always pressure for steering. The
residual flow goes to load handling.
007216
The vane pumps consist of a pump housing and pump assembly. A ro-
tor in the pump assembly comprises a number of centrifugal blades in
1. Hydraulic pump for brake system, cooling and filtra- radial tracks. The rotor is driven via a shaft and rotates in a cam ring.
tion. The rotor blade follows the cam ring profile with two cycles per revolu-
2. Hydraulic oil pump for load handling. tion - suction phase and pressure phase. The flow through the pump
3. Hydraulic oil pump for steering and load handling. travels radially through the pump assembly.
The blade is pressed outward against the cam ring through centrifugal
force and pressure pins, which in turn are pressurised at the same
pressure as the pump emits. This ensures that the blades follow the
cam profile. An oil film sures that the blades do not make contact with
the material of the cam profile. In the same manner, an oil film pre-
vents contact with the side plates.
Because the blades balance each other, the rotor only detects ele-
ments caused by pressure increase. Solid shaft bearings absorb forc-
es caused by the pump drive.
Vane pump flow is direct depending on the speed of the input shaft.
Hydraulic oil pump for brake system, cooling and filtration.

The hydraulic oil pump for brake system, cooling and filtration feeds
the brake system’s brake and cooling circuits via an accumulator
charging valve; see section 4 Brakes, group 4.3.1 Brake fluid pump
and 4.8 Temperature control, cleaning and brake fluid.
The hydraulic oil pump for brake system, cooling and filtration and the
load handling pump are replaced as a unit.

6 10 Common hydraulics – 10.4.3 Vane pump with fixed displacement
Hydraulic oil pump for load handling

The hydraulic oil pump for load handling (position 2) pumps oil to the
load handling control valve.
Hydraulic oil pump for steering and load handling

The hydraulic oil pump for steering and load handling (position 3)
pumps oil to load handling and to steering. The division of pressure be-
tween load handling and steering is handled by the priority valve,
which ensures that steering always has sufficient pressure; see Prior-
ity valve, description page 10.
Vane pump with fixed displacement, replacement

page
–
NOTE
Safety.
2 Clean the hydraulic oil pumps and the areas around them.
Safety.
4 Place a receptacle under the hydraulic oil pumps to catch oil spill.
5 Mark up and detach the hydraulic hoses from the pump.
007586

10 Common hydraulics – 10.4.3 Vane pump with fixed displacement 7
6 Detach the vane pumps.

Remove the retaining bolts, pull out the pumps and move them
forward.
007593
7 Clean the flange on the gearbox, removing all silicone remnants.
CAUTION
Gasket remains could fall down into the gearbox.
Product damage.
Be careful and make sure that no gasket remains fall

down into the gearbox.
007587
8 Transfer the connection adapters and the contact to the new

pump.
NOTE
9 Check the O-ring between the vane pump and gearbox; replace
if necessary. Coast the flange toward the gearbox on the pump
with sealing silicon; see section F Technical data.
007594
10 Fit the vane pumps.

Position the pump and check that the splines engage in the shaft.
NOTE
007595

8 10 Common hydraulics – 10.4.4 Pipes and hoses
11 Connect the hydraulic hoses in accordance with the markings.
007586

14 Check the hose connections, the seal between the pumps and
the seal between the pump and gearbox for leaks.
15 Remove the receptacle. Treat spill oil as environmentally hazard-
ous waste.
004791
16 Check the oil level in the hydraulic system; top up if needed.
NOTE
If the pump is replaced due to malfunction, change the oil
and filter as well.

page
–

10 Common hydraulics – 10.5 Hoses, pipes and valves 9
10.5 Hoses, pipes and valves

page
–
Hoses with ORFS couplings are used almost exclusively. For maxi-
mum service life and function, the following should be observed when
replacing hoses.
1. To avoid stresses in the connection, there should be a length of
straight hose after the connection.
2. The hose may not be twisted. (A twist of 7% reduces service life
by 90%.)
3. Minimise the number of bends by using correct couplings.
4. Avoid sharp bends.
5. Keep the hoses clean internally. Leave the plugs in place as long
as possible when installing.
6. Check the position of the O-rings and tighten to the correct torque,
See section F Technical data.
NOTE
Straight coupling requires a counterhold wrench to prevent
damage to the O-ring.
7. The O-rings must not be oiled when fitted.
Hose length
C/L
Hose length is measured on a laid-out hose between the sealing sur-
faces. On angled connections, measure from the sealing surface's
centre line [C/L] according to the figure.
Cleanliness
The function and service life of hydraulic components depend to a
great extent on how clean the hydraulic oil is. Therefore, it is very im-
portant to prevent dirt from entering the brake and hydraulic system.
Some simple advice to keep the hydraulic system clean.
• Always clean the area around a component before starting to
001015
work.
C/L line for measuring hose length • Plug hose connections immediately after disconnecting. If possi-
ble, use correct plugs for the connection type. If plugs are missing,
use clean plastic bags and cable ties or tape to seal the connec-
tion.
• Never reuse oil that has been drained from the machine.
• If possible, filter the oil before pouring it into the machine. Oil bar-
rels often contain impurities.
When filling hydraulic oil, fill through the caps at the hydraulic oil
filters in the tank so that the oil is filtered.

10 10 Common hydraulics – 10.5.2 Priority valve
10.5.2 Priority valve

Priority valve, description
page
–
The priority valve regulates oil flow from the hydraulic oil pump for load
6
handling and steering so that oil to the steering valve is always priori-
1
tised. The residual flow goes to working hydraulics.
The priority valve is load sensing and pilot pressure compensating.
5 Load sensing means that the valve adapts the control signal to the
steering valve’s consumption. Pilot pressure compensating means
that the priority valve compensates for the pressure drop between the
4
priority valve and steering valve via a separate line.
The priority valve has a built-in pressure limiter on the load signal. The
pressure limiter maximizes the load signal’s pressure.
3
007576
1. Supply pressure from hydraulic oil pump (P)

2. Pilot pressure (PP), pressure drop to steering valve
3. Pressure to control valve, load handling (EF)
4. Load signal from steering valve (LS)
5. Tank draining (T)
6. Pressure to steering valve (CF)
10.5.3 Shuttle valve

Shuttle valve, description
page
–
A shuttle valve chooses between two pressure signals and sends on

the strongest. The shuttle valves are used to sends load signals to the
hydraulic oil pumps. This means that the pumps are controlled by the
function that demands the highest pressure, if several functions are
activated at the same time.
Machines with reversible operator’s seat have an auxiliary brake

pedal for driving rearward. The brake pedal is connected in parallel to
007219
the brake pedal for driving forward. The shuttle valve selects the
strongest pressure signal and forwards it to the wheel brakes.

Accumulator charging valve, description
page
–
See section 4 Brakes, group 4.3.3 Accumulator charging valve.

10 Common hydraulics – 10.5.5 Proportional valves 11
10.5.5 Proportional valves

Proportional valves, description
page
–
The flow in the hydraulic system is proportionally controlled by propor-

tional valves.

12 10 Common hydraulics – 10.6 Temperature control, cleaning and hydraulic oil
10.6 Temperature control,

cleaning and hydraulic oil
Temperature control, cleaning and hydraulic oil,
page
–
˚C
˚C
P2
P1
T
EF PP
P 14 9, 15
P CF D790-2 D795
LS
T LS
T D797-1
L R
8, 10, 13
D7 D10
2 3 4
11 M
P T
6
12
1 1 1
16 5
009737
˚C 7

1 The hydraulic oil pumps pump oil from the See pressure plate on left Vane pump with fixed displacement, de-
hydraulic oil tank. frame beam. scription page 5
2 The brake oil filter cleans the oil. - See Section 4 Brakes, group 4.3.2
Brake oil filter
3 The accumulator charging valve directs oil Charge: P = 20.5 Accumulator charging valve, description
to charging of accumulators or through the ±0.5 MPa page 10
brake system's cooling circuit. Cooling: P < 0.1 MPa
4 The oil passes through the drive axle block. - See Section 4 Brakes, group 4.3.6 Drive
axle block
5 A small amount of oil is guided through the Fine filter hydraulic oil, description page
fine filter and back to the hydraulic oil tank. 23

10 Common hydraulics – 10.6 Temperature control, cleaning and hydraulic oil 13

6 The hydraulic oil cooler lowers the oil tem- - Hydraulic oil cooler, description page 15
perature.
7 The hydraulic oil temperature sensor - Sensor hydraulic oil temperature, de-
(B776) sends the frame control unit (D797- scription page 17
1) a voltage signal proportional to the hy- D7: Diagnostic menu, see section 8
draulic oil temperature. Control system, group 8.4.5.1 HYD,
menu 1
8 The frame control unit (D797-1) transmits Checked by control sys- Section 11 Common electrics, group
oil temperature on the CAN bus. tem; error indicated with 11.5.3.2 Frame control unit (D797-1)
error code.
9 The KID control unit (D795) shows oil tem- - Section 9 Frame, body, cab and acces-
perature in the operating menu hydraulic oil sories, group 9.1 Controls and instru-
temperature. ments
10 If the hydraulic oil temperature is high, the U = 24 V Cooling fan, description page 17
frame control unit (D797-1) supplies volt- D10: Diagnostic menu, see section 8
age to the cooling fan. Control system, group 8.4.5.1 HYD,
menu 1
11 The cooling fan increases the airflow - Cooling fan, description page 17
through the hydraulic oil cooler, thus in-
creasing cooling output
12 If the pressure through the cooler is too P = 0.2 MPa Cooler bypass valve, description page
high, the thermal bypass valve opens and 19
directs the oil past the cooler.
13 If the hydraulic oil temperature is too high, Checked by the control Section 11 Common electrics, group
the frame control unit (D797-1) transmits a system; error shown with 11.5.3.2 Frame control unit (D797-1)
warning for high hydraulic oil temperature error code.
on the CAN bus.
14 The KIT control unit (D790-2) activates the - Section 9 Frame, body, cab and acces-
hydraulic oil temperature warning light. sories, group 9.1 Controls and instru-
ments
15 The KID control unit (D795) shows the er- Checked by the control Section 11 Common electrics, group
ror code on the display. system; error shown with 11.5.3.12 KID control unit (D795)
error code.
16 Return oil from the loading handling control - Cooler bypass valve, description page
valve and the steering valve are cleaned by 19
the oil filters in the hydraulic oil tank.

draulics, Basic machine.

14 10 Common hydraulics – 10.6.1 Tank heater
10.6.1 Tank heater

Tank heater, safety
page
–
CAUTION
The tank heater is connected to high voltage. Connec-
tion and reconnection of the tank heater may only be
performed by personnel authorized for work with high
voltage.
Tank heater, description

page
–
The tank can be equipped with a heater. The tank heater is designed
for cold climates.
The tank heater runs off high current. Heater output is adapted through
different connections and adaptation to different operating voltages -
110, 230 or 400 V AC. Higher voltage generates higher heater output.
The heater is mounted in a hole in the connection cover at the bottom
of the short side of the tank.
The tank heater can be equipped with a programmable thermostat
007583
which maintains the temperature at an even level. The thermostat is

fitted directly onto the heating element and can be adjusted with a
knob on the junction box. Recommended temperature setting is 50-
70 °C.

10 Common hydraulics – 10.6.2 Cooler hydraulic oil 15
10.6.2 Cooler hydraulic oil

Hydraulic oil cooler, description
page
–
The working hydraulics use a through-flow cooler with electric cooling

fan (the same type of cooler as used for the brake system). The oil is
cooled when it passes the cooler, which sits inside the side panel on
the right-hand side behind the hydraulic oil tank.
007577
Hydraulic oil cooler, change

page
–
NOTE
Safety.
2 Drain the oil from the hydraulic oil tank; see Hydraulic oil, chang-
ing page 22.

16 10 Common hydraulics – 10.6.2 Cooler hydraulic oil
3 Mark up and disconnect hydraulic hoses from the cooler. Let the
1 oil in the cooler drain into the collection container.
NOTE
2 Plug all unions at once to protect the hydraulic system from
contamination.
4 Disconnect the cabling from the cooling fan.
5 Remove the attaching bolts and lift away the cooler.
6 Transfer the cooling fan to the new cooler.
8 Connect the cabling to the cooling fan.
9 Connect the hydraulic hoses to the cooler.
NOTE
007667
1. Radiator
2. Cooling fan
3. Hydraulic hose
10 Fill the hydraulic oil tank with oil; see Hydraulic oil, changing page
22. The oil level should be visible in the sight glass.
CAUTION
Overfilling of oil.


10 Common hydraulics – 10.6.3 Cooling fan 17
10.6.3 Cooling fan

Cooling fan, description
page
–
The electric cooling fan is forcing. The cooling fan is located at the rear
of the cooler. The fan draws air from the machine’s outside through the
cooler. Openings in the side cover allows air to pass through the
cooler.
The radiator is supplied voltage by the frame control unit (D797-1)
upon activation. The cooling fan is activated when oil temperature is
65 °C in the hydraulic oil tank and is deactivated when oil temperature
is 55 °C.
The signal can be checked from the diagnostic menu; see section 8
007582
10.6.4 Sensor hydraulic oil temperature

Sensor hydraulic oil temperature, description
page
–
The hydraulic oil temperature sensor (B776) detects the temperature

of the hydraulic oil. The sensor is located on the hydraulic oil tank’s
rear short end.
The sensor detects the oil temperature in the tank and then takes the
accumulated heat in the hydraulic oil into account.
The hydraulic oil temperature sensor (B776) is supplied voltage by the
frame control unit (D797-1) and sends the control unit a voltage signal
proportional to oil temperature.
007666

18 10 Common hydraulics – 10.6.4 Sensor hydraulic oil temperature
Hydraulic oil temperature sensor, change

page
–
NOTE
Safety.

ing page 22.
3 Disconnect the cabling from sensor hydraulic oil temperature
(B776).
4 Change sensor hydraulic oil temperature (B776).
NOTE
009738
1
DCF 370-500
1. Hydraulic oil temperature sensor (B776)
5 Connect the cabling to the sensor.
1
009739
DCF 330
1. Hydraulic oil temperature sensor (B776)

10 Common hydraulics – 10.6.5 Radiator bypass valve 19
CAUTION
Overfilling of oil.

7 Use the display, go to the diagnostic menu, see section 8 Control

DIAG HYDRAULIC 1(X) system, group 8.4.5.1 HYD, menu 1.
HYDRAULIC OIL
TEMP XXX TEMP indicates hydraulic oil temperature in °C. Check that cor-
FAN XY rect temperature is shown.
010070
SET OUTPUT + - X
Diagnostic menu Hyd, menu 1
10.6.5 Radiator bypass valve

Cooler bypass valve, description
page
–
The bypass valve protects the cooler from overpressure. The valve
opens a passage past the cooler directly to the tank if resistance in the
cooler becomes too high.
007578
Bypass valve, replacement

page
–
NOTE
Safety.

20 10 Common hydraulics – 10.6.6 Breather filter hydraulic oil tank

ing page 22.
4 Detach the bypass valve.
NOTE
Note how the bypass valve faces; the valve is marked with
an arrow.
007580
5 Install the new bypass valve, turning the valve to face the same
way as the old. Use Loctite when fitting the bypass valve.
CAUTION
Overfilling of oil.

10.6.6 Breather filter hydraulic oil tank

Breather filter hydraulic oil tank, description
page
–
A breather filter of insert type is mounted on the hydraulic oil tank to

protect the tank from impurities. On top of the filter housing is an indi-
cator that shows when the filter is clogged and should be changed.
007585

10 Common hydraulics – 10.6.7 Oil filter 21
10.6.7 Oil filter

Hydraulic oil filter, description
page
–
The oil in the hydraulic system is cleaned by two return filters located
inside the hydraulic oil tank. The oil is pumped through the cooler and
back through the filters by the cooling pump. All of the return oil from
the load handling functions also passes through the filters.
007581
Hydraulic oil filter, replacement

page
–
NOTE
Safety.
IMPORTANT
Ensure cleanliness around the filter and filling point
when working on the hydraulic tank.
Dirt particles may cause machine damage.

22 10 Common hydraulics – 10.6.8 Hydraulic oil
2 Remove the cover plates (position 1) over the hydraulic oil filters.
3 Lift up the filter unit and place it in the receptacle. Let the hydrau-
lic oil drain.
4 Part the filter unit and remove the filter insert. Handle the filter in-
sert as environmentally hazardous waste. Note the position of the
parts.
1. Cover for oil filter

2. Filling point hydraulic oil
3. Level glass hydraulic oil
5. Breather filter hydraulic oil tank
5 Clean the filter holder’s parts. Be especially thorough with the
magnetic rod.
6 Fit the new filters and assemble the filter units.
7 Install the filter units and the covers. Tighten the screws cross-
wise.
8 Check the oil level in the hydraulic oil tank. The oil level shall be
at the top of the level glass. Top up as needed.
NOTE
Magnetic rod
Check the hydraulic oil level with the fork carriage complete-
ly lowered and the mast tilted all the way in.
10.6.8 Hydraulic oil

Hydraulic oil, changing
page
–
NOTE
Safety.
IMPORTANT
Ensure cleanliness around the filter and filling point
when working on the hydraulic tank.

10 Common hydraulics – 10.6.9 Hydraulic oil fine-filter 23

2 Remove the filler cap and pump out the hydraulic oil in a collec-
tion container.
3 When most possible oil has been pumped out. Place a collection
container under the hydraulic oil tank’s drain plug and drain the
last of the hydraulic oil.
4 Fit the drain plug when the oil has drained.
1. Cover for oil filter NOTE

2. Filling point hydraulic oil Make sure that the seal washer is installed as well.
3. Level glass hydraulic oil
5 If the hydraulic oil filters are to be changed, change them before
filling the tank with oil, see Hydraulic oil filter, replacement page
5. Breather filter hydraulic oil tank
21.
6 Fill new hydraulic oil through the filler holes on the filters’ covers.
This results in filtering of the oil that is filled and protects the hy-
draulic system from impurities.
Fill oil until the oil level is in the middle of the level glass. For vol-
ume and grade, see section F Technical data.
10.6.9 Hydraulic oil fine-filter

Fine filter hydraulic oil, description
page
–
The fine filter is located behind the hydraulic oil tank on the right side
of the machine. The filter is connected to hydraulic oil pump cooling
and filtration. The filter is connected in parallel to the hydraulic oil filters
in the hydraulic oil tank.
Oil is pumped from the hydraulic oil tank through the fine filter and then
back to the hydraulic oil tank.
The fine filter cleans a smaller amount of oil but with a higher degree
of filtration when the machine is running.
007579

24 10 Common hydraulics – 10.6.10 Pipes and hoses
Hydraulic oil fine filter, replacement

page
–
NOTE
Safety.
IMPORTANT
Make sure that the area around the filter is clean when
working.

2 Remove the cover.
3 Lift up the filter insert. Place it in a receptacle and let the hydraulic
oil drain.
4 Fit the new filter insert and refit the cover over the fine filter.

page
–

10 Common hydraulics – 10.7 Auxiliaries 25
10.7 Auxiliaries
10.7.1 Hydraulic cylinders
page
–
Fault tracing, leakage
CAUTION
All fault tracing should be carried out with as low a
pressure in the system as possible so that the leak-
age can be detected. High pressure causes the seals
to close tighter, which prevents detection of leaks.
1 Carefully check the source of the leakage before taking any ac-
tion. It may be possible to rectify the fault without disassembly.
2 Check for external leakage:
• At cylinder end welds
• At sleeve coupling welds
• Between cylinder barrel and cylinder head
This could be due to a defective O-ring or damaged O-ring
sealing surfaces. Both faults can be rectified with the cylinder
in situ.
• Between cylinder head an piston rod
This could be due to a damaged piston rod or damaged or
worn piston rod seal.
3 Check for internal leakage. Pressurise the cylinder and check
whether the piston sinks back.
1. Piston
2. Scraper This could be due to a worn piston seal.
3. Cylinder head
4. Piston rod seal Dismantling of cylinders
5. O-ring with thrust ring
6. Cylinder barrel
7. Sleeve coupling CAUTION
8. Welded cylinder end
9. Piston
Before dismantling always check that the piston rod
10. Piston seal, double-acting
is clean and free from all residual paint. Also check
11. Example of weld
that connections and couplings are free from burrs
and impact marks. Make sure that the chamfer up to
the chromium surface of the piston rod is free from
burrs and residual paint.
1 Remove the cylinder from its mounting and undo the connec-
tions.
2 Plug the cylinder connections and hoses without delay.

26 10 Common hydraulics – 10.7.1 Hydraulic cylinders
3 If the cylinder is opened - observe the strictest cleanliness!
Inspection of surfaces
1 Inspect the sealing surfaces. Always bearing mind the function of
the seals and the type of sealing surfaces they have. See the fol-
lowing descriptions:
• O-ring groove, internal and external
• piston rod seal in the cylinder head
• sealing groove on the piston
• cylinder barrel surface
• piston rod surface. The piston rod is chromium plated with a
layer thickness of 20-50 my. Slight damage to the chromium
plating may not necessarily be the direct cause of leakage.
• all sliding surfaces (dynamic surfaces), e.g. cylinder barrel
and piston rod. These are always the hardest to seal.
CAUTION
When fitting the cylinder head:
Get it absolutely straight. This is best done by hand.

Under no circumstances hit it with any mallet. If the
cylinder head is fitted crooked, the sealing lip of the
piston rod seal could be damaged, making an improp-
er seal. This applies to all types of piston rod seals.

10 Common hydraulics – 10.7.1 Hydraulic cylinders 27
Function and removal of the seals
Piston rod seal

The piston rod seal is the seal that sits in the groove in the cylinder
2
head and seals against the piston rod. This seal is greatly subject to
wear since it is both a dynamic and a static seal, i.e. it seals against a
1 moving surface on the piston rod while the sealing surface with the cyl-
inder head is fixed. There are different types of piston rod seals:
• Single V-ring seal
• Pre-stressed V-ring seal with thrust ring
3 • Compressible seal
The simple V seal has a V-shaped section with two lips that seal in
opposite directions. The hydraulic pressure works in the V-shape,
4
6 pressing the sealing lips out towards the sealing surfaces on the piston
rod and in the cylinder barrel. Even minor damage to the sealing lips
can generate large leaks. Examine the sealing lips by carefully using
a fingernail to feel around the seal. To remove, use a screwdriver to
prise the seal outward and bend it up (see illustration). It is extremely
important that the screwdriver is always inserted in the V shape so that
it cannot touch and thereby damage a sealing surface. A mark from a
screwdriver on a sealing surface can have a devastating effect and
001497
5 cause major leakage.
1. Hydraulic pressure
2. The sealing lip is pressed outward toward the piston
rod
3. The sealing lip is pressed inward toward the cylin-
der head
4. Piston rod sealing surface
5. Cylinder head sealing surface
6. Screwdriver

The pretensioned V seal also has an O-ring in the seal’s V-shaped

2
space. The O-ring creates a strong seal at low hydraulic pressure
1 since the O-ring already presses the sealing lips out toward the sealing
surfaces when unloaded. It is just as sensitive to damage as the V
seal. Examine in the same manner. To remove, use a screwdriver to
prise the seal outward and bend it up (see illustration). It is extremely
important that the screwdriver is always inserted in the V shape so that
3 it cannot touch and thereby damage a sealing surface. A mark from a
7
screwdriver on a sealing surface can have a devastating effect and
6 4 cause major leakage.
001498
5
rod
der head
6. Screwdriver
7. O-ring

The compressible piston rod seal consists of a solid rubber profile

2
and provides a larger sealing surface than the V seals. To remove, use
a screwdriver to prise the seal outward and bend it up (see illustration).
1
With this type of seal with sealing surfaces that cover so much of the
3 seal groove, it is particularly important that marks are not made with
the screwdriver.
Thrust ring and O-ring

3
6
4
5
001499
5
rod
der head
6. Screwdriver
The thrust ring and O-ring combination is used for sealing between two
fixed surfaces, such as between cylinder barrel and cylinder head.
The purpose of the thrust ring is to lend rigidity to the O-ring so that it
is not deformed. The O-ring is pressed against the thrust ring and the
sealing surface by the hydraulic pressure in the cylinder.
3
When the cylinder head is mounted in the barrel: Take extreme care
not to damage the O-ring.
4
2
001506
1
2. O-ring
3. Support ring

Scraper
øD+10
The purpose of the scraper is to scrape the piston rod clean and pre-
1 vent impurities from entering the cylinder barrel.
The scraper is fitted with a special fitting tool, which has a greater outer
diameter than the scraper so that the press force against the scraper
2 ceases right when the scraper is pressed into position. If the scraper
were to be pressed in further, the metal capsule will be deformed (see
lower illustration), which would impair the function of the scraper.
4
To prevent the scraper from bottoming in its recess in the cylinder
3 head, the recess is slightly deeper than the width of the scraper.
øD
6
001496
1. Correct fitting tool

2. Scraper, correctly fitted
3. Cylinder head
4. Play between scraper and bottom of cylinder head
recess
5. Incorrect fitting tool
6. Deformed scraper
A screwdriver can be used for removal. This must always be applied
1 against the outer edge of the scraper (see illustration). Carefully tap
the screwdriver down between the scraper and the cylinder head and
2 then prise out the scraper. Polish away any damage to the cylinder
head.
CAUTION
3 No tool must be applied from the inside. This could
give rise to burrs on the cylinder head which could in
turn damage the piston rod. Burrs may also damage
the piston rod seal when fitting the piston.
001551
1. Screwdriver
2. Scraper
3. Cylinder head

On the single-acting V-ring seal it is always the long side that seals
2
against the fixed surface and the short side that seals against the mov-
ing surface.
1 To remove, use a screwdriver to prise the seal outward and bend it up
(see illustration). It is extremely important that the screwdriver is al-
ways inserted in the V shape so that it cannot touch and thereby dam-
age a sealing surface. A mark from a screwdriver on a sealing surface
3 can have a devastating effect and cause major leakage.
6 4
002370
5
2. Seal is pressed outward towards the cylinder barrel
3. Seal is pressed inward toward the piston
4. Cylinder barrel sealing surface
5. Piston sealing surface
6. Screwdriver
The seal must always be fitted as an assembly together with the thrust
ring.
Always assemble by hand. No tools should be used as they could eas-
ily damage the surface of the piston.
For easier assembly the seal can be heated in hot water to make it
soft.
Lubricate with hydraulic oil.
002950
Double-acting piston seal

5 4 3 1 6
The double-acting seal functions with pressure from both sides, e.g. in
a steering cylinder.
All of the interior surface of the cylinder barrel is a sealing surface and
it is therefore extremely important that it is completely free from dam-
age.
Exercise care when fitting the piston in the cylinder barrel, making sure
2
that the seal is not damaged by the cylinder barrel threads.
002951
1. Moving sealing surface to cylinder barrel Dismantling:

2. Fixed sealing surface with piston
1 Remove guide rings and thrust rings.
3. Guide ring
4. Thrust ring 2 Move the seal over to one side of the sealing groove.
5. Piston head 3 Press it up so that there is a gap between seal and piston.
6. Cylinder barrel

4 Without damaging the surface of the piston - cut off the seal with
a knife.
5 Carefully examine the seal to find any damage that can cause
leakage. This will be easier if you bend the seal sharply bit by bit
and feel over the sealing surface with a fingernail.
Assembly:
1 All double-acting piston seals are of similar design: a middle seal-
ing body. then thrust rings and farthest out guide rings.
2 First fit the sealing body, then the thrust rings and finally the guide
rings - all must be done by hand without tools to avoid damage.
Repairing the piston rod surface

A small impact mark on a piston rod may be sufficient to cause leak-
1 2 3
age. The chromium plating on the piston rod has a thickness of 20-50
my and can be treated to make good minor damage. This may be a
satisfactory alternative to costly disassembly.
1 Locate the damage using your fingertips and fingernails.
4 2 Use a small, highly-polished hammer and work the surrounding

material inwards towards the damage, starting from the outside.
3 Instead of a small sharp mark there will now be a small uniform
concavity in the chromium plating.
4 Polish with emery cloth, progressing from number 240 to 600.
Wrap the emery cloth round a file to give it good support. Note
that there must always be chromium plating present at the dam-
age.
5 It is important to treat small impact marks before disassembly and
assembly to avoid damaging the cylinder head.
6 Repairing larger damage on a piston rod
002952
• fill the damage with weld metal, use chromium or stainless

1. Piston steel electrodes
2. Chromium plating • remove all slag completely
3. Impact marks
• file the weld down to the same level as the chrome
4. Highly-polished hammer
• polish evenly using emery cloth

Dismantling steering cylinders

It can prove extremely difficult to extract the piston rod from the cylin-
der barrel on steering cylinders because the O-ring in the cylinder
head fastens in the retaining ring groove in the cylinder barrel. It is
therefore best to remove the O-ring before trying to withdraw the pis-
ton rod from the cylinder.
1 Unscrew the end washer at the cylinder head.

2 Unscrew the connecting nipple for the hydraulic hose.
3 Insert the piston rod with piston crown until the O-ring is visible
through the nipple hole.
4 Bend the end of a length of heavy-duty steel wire, piano wire or
the like into the shape of a hook. Use this to snag the O-ring.
5 Pull the O-ring up slightly and hold it with a pair of needle-nose
pliers.
6 Continue to pull the O-ring out through the hole.
7 Hold the O-ring steady and cut it with a knife.
8 Rotate the piston rod while pulling the O-ring out through the
hole.
9 Remove the retaining ring from the cylinder barrel.
10 Carefully extract the piston rod from the cylinder barrel.
002953


11 Common electrics 1
11 Common electrics
Table of Contents 11 Common electrics

mm mm mm mm mm mm
11 Common electrics .......................................................................................... 3

11.2 Electric protection ....................................................................................... 3
11.2.1 Battery disconnect switch ...................................................................... 3
11.2.2 Fuses ..................................................................................................... 3
11.2.3 Emergency stop switch .......................................................................... 3
11.3 Batteries ..................................................................................................... 4
11.3.1 Start battery ........................................................................................... 4
11.4 Alternator .................................................................................................... 6
11.4.1 Alternator ............................................................................................... 6
11.5 Distribution of electricity ............................................................................. 7
11.5.1 Power supply ......................................................................................... 7
11.5.2 Electrical distribution box ..................................................................... 14
11.5.3 Control units ......................................................................................... 16
11.5.5 Cables .................................................................................................. 26
11.6 Communication ........................................................................................ 37
11.6.1 CAN-bus .............................................................................................. 37
11.6.2 Redundant CAN bus ............................................................................ 39
11.6.3 CAN bus drivetrain ............................................................................... 41
11.6.4 Communication between PC and machine .......................................... 42
11.6.5 RMI (Remote Machine Interface) ......................................................... 43

2 11 Common electrics

11 Common electrics – 11 Common electrics 3
11 Common electrics
mm mm mm mm mm mm
11.2 Electric protection

11.2.1 Battery disconnect switch
Battery disconnect switch, description
page
–
The positive terminals of the batteries connected in series are con-

nected to the machine’s electrical system via the battery disconnect
switch. The battery disconnector cuts off all power from the batteries
to the machine’s electrical system.
IMPORTANT
Never turn off the voltage with the battery disconnect
switch when the engine is running. This could dam-
007682
A
age the alternator.
A. Position of battery disconnect switch
The battery disconnect switch must not be used for
emergency stop!
11.2.2 Fuses
Fuses, replacement
page
–
When checking and replacing the main fuse:

1. Switch off the main current (battery disconnect switch).
2. Remove the plastic cover.
3. Check that fuses are intact. Replace if necessary.
The fuses are 25 A.
When checking and replacing the fuse:
1. Switch off the main current (battery disconnect switch).
2. Remove the cover of the electrical distribution box.
3. Check and, if necessary, replace fuses.
The fuse chart provides information about each fuse.
11.2.3 Emergency stop switch

Emergency stop, description
page
–
See Emergency stop switch voltage (15E), function description page

11.

4 11 Common electrics – 11.3 Batteries
11.3 Batteries
11.3.1 Start battery
Start battery, description
page
–
The machine’s electrical system is supplied by two 12 V batteries con-

nected in series.
The negative terminal is connected to the frame. The positive terminal
is connected to the battery disconnector.
The batteries are charged by the alternator, see Alternator, description
page 6.
WARNING
Battery electrolyte contains corrosive sulphuric acid
Risk of corrosive injuries, health hazard!
Immediately remove electrolyte from the skin. Wash

with soap and copious amounts of water. If electrolyte
gets in the eyes, rinse with copious amounts of water
and seek medical help immediately.
WARNING
Risk of explosion!
Personal injury!
During charging, hydrogen gas forms around the bat-

teries. Sparks could ignite the hydrogen gas, causing
an explosion. Disconnect the battery with the battery
disconnect switch.
WARNING
Risk of explosion if the battery short circuits (also
causes loss of capacity).
Fire hazard, personal injury!
The battery's terminals may not be connected to each

other or commonly to ground (chassis).

11 Common electrics – 11.3.1 Start battery 5
Starter battery, replacement

page
–

2 Disconnect the cables from the battery terminals, starting with the
negative (minus) cable.
3 Replace the batteries.
4 Connect the cables to the battery terminals. Connect the nega-
tive cable last of all.
NOTE
Take great care when reconnecting the cables to prevent
short circuiting.

6 11 Common electrics – 11.4 Alternator
11.4 Alternator
11.4.1 Alternator
Alternator, description
page
–
The alternator generates current during operation and supplies this to

the batteries. The alternator produces AC current and has an integrat-
ed charge regulator.
The alternator is driven by the engine via a belt. Faults are indicated
by the warning lamp for low battery charging.
The signal can be checked from the diagnostic menu, section 8 Con-
trol system, section 8.4.6.4 ENGINE, menu 4.
1 2
007283
1. Alternator (Volvo engine)

2. Alternator (Cummins engine)
Alternator, replacement
page
–
See supplier documentation, engine.

11 Common electrics – 11.5 Distribution of electricity 7
11.5 Distribution of electricity

11.5.1 Power supply
11.5.1.2 Redundant voltage feed of control
units
Redundant voltage feed for control units, description of
page
–
operation
1 2 3 4 5
D1 D3 D4 D5
D2
D793 D794
- +
D9
D790-1 D797-2
6, 7 9
10 8
D795 D790-2 D797-1
009740
D10 D8

1 The NC switch, operator’s door (S U = 24 V Section 9 Frame, body, cab and accessories , group
266-LE) or the NC switch, passen- 9.10.2 Doors
ger door (S 266-RI) sends a volt- D1: Diagnostic menu, see section 8 Control system,
age signal to the cab control unit group 8.4.2.9 LIGHTS, menu 9 or 8.4.11.5 MOVE-
(D790-1) when the door is opened. CAB, menu 1
2 The interior lighting switch of the U = 24 V Section 9 Frame, body, cab and accessories, group
KIT control unit (D790-2) sends a 9.6.12 Interior lighting
voltage signal to the cab control D2: Diagnostic menu, see section 8 Control system,
unit (D790-1). group 8.4.2.13 LIGHTS, menu 13
3 The switch for warning lights U = 24 V Section 9 Frame, body, cab and accessories, group
(S109) sends a voltage signal to 9.6.7 Warning lights
the cab control unit (D790-1). D3: Diagnostic menu, see section 8 Control system,
group 8.4.2.5 LIGHTS, menu 5
4 When the ignition switch (S150) is U = 24 V Section 9 Frame, body, cab and accessories, group
turned to position I, it sends a volt- 9.1 Controls and instruments
age signal to the cab control unit D4: Diagnostics menu, see section 8 Control system,
(D790-1). group 8.4.1.5 CAN/POWER, menu 5

8 11 Common electrics – 11.5.1.2 Redundant voltage feed of control units

5 The switch for entry lighting (S141) U = 24 V Section 9 Frame, body, cab and accessories, group
sends a voltage signal to the cab 9.6 Lighting
control unit (D790-1). D5: Diagnostic menu, see section 8 Control system,
group 8.4.2.15 LIGHTS, menu 15
6 The cab control unit (D790-1) acti- - Cab control unit (D790-1), description page 17
vates a hold circuit, which acti-
vates the control unit’s control
logic.
7 The cab control unit (D790-1) acti- UK11:7 = 24 V Cab control unit (D790-1), description page 17
vates a redundant voltage feed to
UK11:8 = 24 V
other control units.
UK11:9 = 24 V
The cab control unit (D790-1) has
4 outputs for redundant voltage UK11:10 = 24 V
feed while other control units have
two inputs for redundant voltage
feed. In case of a malfunction of
one voltage feed the control unit is
supplied by the other feed.
8 The cab control unit (D790-1) sup- UK2:7 = 24 V Frame control unit (D797-1), description page 18
plies voltage to the control logic of D8: Diagnostic menu, see section 8 Control system,
UK2:8 = 24 V
the other control units via the re- group 8.4.1.10 CAN/POWER, menu 10
dundant voltage feed.
9 UK2:7 = 24 V Frame control unit (D797-2), description page 19
UK2:8 = 24 V D9: Diagnostic menu, see section 8 Control system,

group 8.4.1.13 CAN/POWER, menu 13
10 UK2:7 = 24 V D10: KID control unit (D795), description page 25
UK2:8 = 24 V Diagnostic menu, see section 8 Control system,


11 Common electrics – 11.5.1.3 Ignition voltage (15) 9
11.5.1.3 Ignition voltage (15)

Ignition voltage (15), description of operation
page
–

Battery disconnect switch In position 1 Battery disconnect switch, description page 3
Redundant voltage feed Activated Redundant voltage feed for control units, description of op-
eration page 7
Redundant CAN bus Communication estab- Redundant CAN bus, description page 39
lished
- +
K315-2
1 2 K315-1
7 3, 6
D1 D2 D3 3
D794
D793
11 D11
4, 5
D8 D10
D790-1 D797-2
2, 8 10
9
D795 D790-2 D797-1
009741
D9

1 The switch for warning lights U = 24 V Section 9 Frame, body, cab and accessories, group 9.6.7
(S109) sends a voltage sig- Warning lights
nal to the cab control unit D1: Diagnostic menu, see section 8 Control system,
(D790-1). group 8.4.2.5 LIGHTS, menu 5
2 When the ignition switch U = 24 V Section 9 Frame, body, cab and accessories, group 9.1
(S150) is turned to position I, Controls and instruments
it sends a voltage signal to D2: Diagnostic menu, see section 8 Control system,
the cab control unit (D790- group 8.4.1.5 CAN/POWER, menu 5
1).
3 The cab control unit (D790- U = 24 V Cab control unit (D790-1), description page 17
1) supplies voltage to igni- D3: Diagnostic menu, see section 8 Control system,
tion voltage relay K315-1 in group 8.4.1.5 CAN/POWER, menu 5
the frame electrical distribu-
tion box and ignition voltage
relay K315-2.

10 11 Common electrics – 11.5.1.3 Ignition voltage (15)

4 Ignition voltage relay K315- U = 24 V -
1 supplies voltage to fuse
holder in the cab electrical
distribution box and in the
frame electrical distribution
box.
5 The fuses feed voltage to U = 24 V -

control units, relays, sole-
noid valves and other elec-
tronic components.
6 Ignition voltage relay K315- U = 24 V Engine control unit (D794), description (Volvo engine)
2 supplies voltage to the en- page 21
gine control unit (D794). Engine control unit (D794), description (Cummins
QSB6.7 engine) page 22
Engine control unit (D794), description (Cummins
QSM11 engine) page 23
7 Drivetrain’s CAN-bus estab- Checked by control sys- Drivetrain CAN bus, description page 41
lishes communication. tem, error shown with
error code.
8 Ignition voltage to the cab UK1:2 = 24 V Cab control unit (D790-1), description page 17
UK1:3 = 24 V
UK1:4 = 24 V
9 Ignition voltage to the frame UK2:1 = 24 V Frame control unit (D797-1), description page 18
UK2:9 = 24 V
UK2:10 = 24 V
10 Ignition voltage to the frame UK2:1 = 24 V Frame control unit (D797-2), description page 19
UK2:9 = 24 V
UK2:10 = 24 V
11 Ignition voltage to the trans- UA1 = 24 V Transmission control unit (D793), description page 20
mission control unit (D793). D11: Diagnostic menu, see section 8 Control system,

11 Common electrics – 11.5.1.4 Emergency stop switch voltage (15E) 11
11.5.1.4 Emergency stop switch voltage (15E)

Emergency stop switch voltage (15E), function description
page
–

Redundant voltage feed Activated Redundant voltage feed for control units, description of operation
page 7
Ignition voltage Activated Ignition voltage (15), description of operation page 9
Emergency stop switch Not activated Section 9 Frame, body, cab and accessories , group 9.1 Controls
and instruments
D794
D793
D5
K3007
3, 4 6
K3009-1 K3009-2
- +
K3002
D4
D2
D7
D790-1 D797-2 D797-1

1, 2, 5 7
009742
D795 D790-2

1 Ignition voltage is activated by the cab con- Checked by control Ignition voltage (15), description of opera-
trol unit (D790-1). system, error shown tion page 9
with error code.
2 The cab control unit (D790-1) supplies volt- UK3009-1/86 = 24 V Cab control unit (D790-1), description page
age to the emergency stop switch voltage 17
relay (K3009-1) in the frame electrical distri- D2: Diagnostic menu, see section 8 Control
bution box. system, group 8.4.1.6 CAN/POWER,
menu 6
3 The emergency stop switch voltage relay UK3009-2/87 = 24 V Electrical distribution box frame, descrip-
(K3009-1) supplies voltage to the emergen- tion page 15
cy stop switch voltage relay (K3009-2) in the
frame electrical distribution box.

12 11 Common electrics – 11.5.1.4 Emergency stop switch voltage (15E)

(K3009-1) also sends a voltage signal to the tion page 15
UK3009-2/87 = 0 V
cab control unit (D790-1), which verifies that D4: Diagnostic menu, see section 8 Control
emergency stop switch voltage relay system, group 8.4.1.6 CAN/POWER,
K3009-1 is active but emergency stop menu 6
switch voltage relay K3009-2 is inactive.
This verifies that the operation breaker is
working.
5 The cab control unit (D790-1) activates the UK3009-2/86 = 24 V Cab control unit (D790-1), description page
emergency stop switch voltage relay 17
(K3009-2) in the electrical distribution box. D5: Diagnostic menu, see section 8 Control
system, group 8.4.1.6 CAN/POWER,
menu 6
K3009-2 supplies voltage to emergency tion page 15
stop switch circuit.
7 The control units are suppled with emergen- Emergency stop Frame control unit (D797-2), description
cy stop switch voltage as long as emergen- switch in home posi- page 19
cy stop switch is not pressed in. tion: U K2:1 = 24 V D7: Diagnostic menu, see section 8 Control
If the emergency stop switch is pressed, ig- system, group 8.4.1.13 CAN/POWER,
nition voltage to the cab control unit (D790- menu 13
1) is cut off, thereby cutting off control cur-
rent to emergency stop switch voltage relay
K3009-1, emergency stop switch voltage re-
lay K3009-2, the tilt relay (K3002) and the
lift/lower relay (K3007). The power supply to
the control units is cut off and the functions
cease.
As an extra safety measure, the cab control
unit (D790-1) also transmits the status of the
emergency stop switch the CAN bus. Thus,
functions are also cut off at the signal level.

11 Common electrics – 11.5.1.5 Voltage converter 13
Emergency stop switch, checking

page
–
1 Start the machine and active any load handling function.

2 Activate lift.
3 Press in the emergency stop switch and check that the lift move-
002084
ment stops.
4 Reset the emergency stop switch (turn in the arrows’ direction)
Emergency stop switch
and check that the lift function works again.
11.5.1.5 Voltage converter

Voltage converter, description
page
–
The voltage converter is located under a protective casing to the left

behind the operator’s seat.
The voltage converter converts 24 volts to 12 volts. 12 V power is
available for accessories through a connector in the cab electrical dis-
tribution box and through a socket on the instrument panel.
Connector X901 in cab electrical distribution box (contains 15-voltage,
30-voltage, ground and 12 V).
Voltage converter, replacement

page
–

2 Remove the covers behind the operator’s seat.
3 Detach the electrical cables from the converter.
4 Remove the voltage converter.
The voltage converter is located behind the operator’s

seat.

14 11 Common electrics – 11.5.2 Electrical distribution box
11.5.2 Electrical distribution box

11.5.2.1 Electrical distribution box cab
Electrical distribution box cab, description
page
–
The electrical distribution box is mounted on the rear wall of the cab,
on the left. Located there are:
• Control unit cab (D790-1).
7 • Circuit fuses.
• Buzzer for alarm if, for example, the operator leaves the machine
without the parking brake being applied.
• Connectors.
• Relays.
•
Voltage converter 24 V to 12 V.
• Connector customer accessory. Output voltage 24 V, max. 10 A.
1
Connector 9-pin Universal mate-n-lock. For part number see
Spare parts catalogue.
2
The connector contains the following connections:
3 1. Ignition voltage
2. Battery voltage
4
3. Ground
5
4. 12 V voltage from the voltage converter
6
NOTE
010630
This connector is not on the machine if the machine is

1. Cab control unit (D790-1) equipped with voltage converter.
2. Socket for control unit programming
3. Socket for CAN bus drivetrain
4. Fuse holder
5. Connector, customer accessory 24V / 10A (X067)
CAUTION
6. Voltage converter
Connector X067 is to be used to connect auxiliary
7. Terminating resistor
electrical equipment. Use of other connections could
overload the wiring and cause product damage.

11 Common electrics – 11.5.2.2 Electrical distribution box frame 15
11.5.2.2 Electrical distribution box frame

Electrical distribution box frame, description
page
–
The electrical distribution box is mounted on the side of the machine.

5 6
4 Also located there are:
7
3 • Circuit fuses.
2
8 • Socket for programming transmission control unit (D793).
1
• Main fuses.
• Transmission control unit (D793).
9
• Power relays for voltage feed to the machine’s functions.
10
11
12
13
007958
14
1. Circuit breakers, emergency stop switch voltage
(15E)F58-3
2. Circuit breakers, ignition voltage (15) F58-2
3. Circuit breakers, battery voltage(30) F58-1
4. Diagnostic socket, engine, VODIA (Volvo engine)
5. Diagnostic socket, transmission
6. Main fuses
7. Transmission control unit TCU (D793)
8. Connection terminal, feed KDU attachment
9. Relay, lift/lower K3007
10. Relay, tilt in/out K3002
11. Relay, ignition switch K315-1
12. Relay, ignition switch K315-2
13. Output relay, emergency stop switch K3009-1
14. Output relay, emergency stop switch K3009-2
-
1
-
2
- 1
3
-
4
5 -
-
6
007184
1. Termination resistor

16 11 Common electrics – 11.5.3 Control units
11.5.3 Control units

Control units, position
page
–
1 2 3
009745
9 8 7 6
1. Control unit KID (D795) 6. Engine control unit, Cummins QSM11 (D794)
2. Control unit KIT (D790-2) 7. Transmission control unit (D793)
3. Control unit cab (D790-1) 8. Frame control unit (D797-1)
4. Control unit, Volvo engine (D794) 9. Frame option control unit (D797-2)
5. Engine control unit, Cummins QSB6.7 (D794)

11 Common electrics – 11.5.3.1 Control unit cab (D790-1) 17
11.5.3.1 Control unit cab (D790-1)

Cab control unit (D790-1), description
page
–
The cab control unit (D790-1) is the central control unit of the control
2 1
system. The cab control unit (D790-1) sends activation signals to other
units and controls and monitors their functions. It administrates work
in the control unit network. The control unit controls the redundant volt-
age feed and handles communication via a redundant CAN bus and
gateway for the drivetrain CAN bus. The cab control unit (D790-1) also
processes all input signals from cab controls and transmits these sig-
5 6 nals on the CAN bus.
4
3
000041
2 The cab control unit has four indicator lights that indicate the control
1. Connection terminals for fan, work lights, wind- unit’s function (see illustration).
screen wiper
2. Connection terminals, other Light 1 Green light on when there is battery voltage to the unit.
3. Light 1, battery voltage The light is physically controlled by voltage feed to the
4. Light 2, redundant voltage feed, redundant CAN control unit.
bus and power supply Light 2 Flashes green when the redundant voltage feed to the
5. Light 3, communication control units and redundant CAN bus communication
6. Light 4, fault indication are active. No power in the system.
Shines with a steady green when power electronics
and 15-voltage are supplied voltage.
Light 3 Long single flash yellow during communication with the

control unit display (D795). This is a basic condition of
fault tracing.
Short single flash yellow during communication with
the engine control unit (D794) and transmission control
unit (D793).
Double flash yellow (short and long flash) during com-
munication with the display and engine or transmis-
sion.
Light 4 Red light on at active error.
Control unit cab, change

page
–

2 Remove the cover from the electrical distribution box.
3 Unplug the cab control unit (D790-1) connectors.
4 Change control unit.
5 Check that the new control unit matches the machine’s forklift
number (Z-number).
6 Calibrate the new control unit; see section 8 Control system,
group 8.5.2.3 Calibrate DRIVETRAIN.

18 11 Common electrics – 11.5.3.2 Frame control unit (D797-1)
11.5.3.2 Frame control unit (D797-1)

Frame control unit (D797-1), description
page
–
The frame control unit (D797-1) processes input data from sensors
1 and sends control signals to relays and solenoid valves.
The control unit has four indicator lights that indicate the control unit’s
2
function (see illustration).
3
Light 1 Green light on when there is battery voltage to the unit.
4 The light is physically controlled by voltage feed to the
control unit.
Light 2 Flashes green when one or more of the following is

missing: redundant voltage feed left, redundant volt-
age feed right or 15-voltage.
000043
6 5 Shines green when redundant voltage feed left, redun-

1. Light 1, battery voltage dant voltage feed right and 15-voltage are supplied
2. Light 2, redundant voltage feed and power supply voltage.
3. Light 3, communication
Light 3 Single yellow flash during communication with display
4. Light 4, fault indication
(KID) or cab control unit (D790-1).
5, Control signals (input and output signals)
6. Power feed (redundant voltage feed control units, Double yellow flash during communication with display
redundant CAN bus) and input data and cab control unit (D790-1).
Frame control unit (D797-1), replacement

page
–

2 Detach the cables from the frame control unit (D797-1).
number (Z-number).
5 Calibrate the new control unit; see section 8 Control system ,
group 8.5.2.1 Calibrate SCALE.

11 Common electrics – 11.5.3.3 Frame control unit (D797-2) 19
11.5.3.3 Frame control unit (D797-2)

Frame control unit (D797-2), description
page
–
The frame control unit (D797-2) processes input data from sensors
1 and sends control signals to relays and solenoid valves.
The control unit has four indicator lights that indicate the control unit’s
2
function (see illustration).
3
Light 1 Green light on when there is battery voltage to the unit.
4 The light is physically controlled by voltage feed to the
control unit.
Light 2 Flashes green when one or more of the following is

missing: redundant voltage feed left, redundant volt-
age feed right or 15-voltage.
000043
6 5 Shines green when redundant voltage feed left, redun-

1. Light 1, battery voltage dant voltage feed right and 15-voltage are supplied
2. Light 2, redundant voltage feed and power supply voltage.
3. Light 3, communication
Light 3 Single yellow flash during communication with display
4. Light 4, fault indication
(KID) or cab control unit (D790-1).
5, Control signals (input and output signals)
6. Power feed (redundant voltage feed control units, Double yellow flash during communication with display
redundant CAN bus) and input data and cab control unit (D790-1).
Frame control unit (D797-2), replacement

page
–

2 Detach the cables from the frame control unit (D797-2).
number (Z-number).
5 Calibrate the new control unit; see section 8 Control system ,
group 8.5.2.2 Calibrate STEERING.

20 11 Common electrics – 11.5.3.9 Transmission control unit (D793)
11.5.3.9 Transmission control unit (D793)

Transmission control unit (D793), description
page
–
The transmission control unit (D793) is part of drivetrain control and

1 2 3
handles gearbox function, selection of gear at load and engine speed,
etc.
The transmission control unit (D793) is connected via separate CAN
D
M bus communication to the engine, which is connected to the cab con-
E
F S trol unit (D790-1). The cab control unit (D790-1) sends drivetrain infor-
mation on to other units.
The control unit has two function keys and three status lights (see il-
lustration).
000045
Function button M Select display group.
1. Display Function button S Select display group mode.
2. Status lights
3. Function keys Status light D Yellow light indicates test mode.
Status light E Yellow light indicates fault in unit.
Status light F Red light during reset.
Control units can show information in the display in three display

groups with various status information. The M and S function keys are
used to navigate in the display and select display group and status in-
formation.
The following status information can be shown in the display:
Display group I
• GPOS - shows transmission’s direction of rotation
• VSPD - shows speed in km/h
• dist - shows distance driven in km or miles
Display group II
• CPOS - shows gear position
• Tspd - shows measured turbine speed in km/h or mph
• Espd - shows measured engine speed in rpm
• Ospd - shows measured speed out from the transmission in rpm
• Srat - shows the turbine speed ratio (Tspd)/engine speed (Espd)
• TQ I - shows measured torque (Nm) of transmission in
• Ttmp - shows measured temperature in the oil sump (Celsius or
Fahrenheit)
• Ctmp - shows measured temperature in the converter (Celsius or
Fahrenheit)
Display group III
• Err - shows error codes (current and history)

11 Common electrics – 11.5.3.10 Engine control unit (D794) 21
Transmission control unit, replacement

page
–

2 Detach the cables from the transmission control unit (D793).
1 3 Change control unit.

number (Z-number).
5 Calibrate the new control unit; see section 8 Control system,
group 8.5.2.3 Calibrate DRIVETRAIN and section 2 Transmis-
sion, group 2.8 Control system, transmission.
007959
1. Control unit transmission
11.5.3.10 Engine control unit (D794)

Engine control unit (D794), description (Volvo engine)
page
–
The engine control unit (D794) is part of drivetrain control and handles
1 engine function, fuel injection, etc.
The engine control unit (D794) is connected via separate CAN bus
2 communication to the gearbox, which is connected to the cab control
unit (D790-1). The cab control unit (D790-1) sends drivetrain informa-
3 tion on to other units.
The control unit is located on the engine has no function keys or dis-
play. All functions are controlled via the CAN bus and an external con-
trol system.
007424
The control unit monitors the following values to optimize engine per-
Engine control unit formance.
1. Cooling passages (fuel) • engine rpm
2. Connector A (black)
• camshaft’s position
3. Connector B (grey)
• boost pressure
• charge-air temperature
• coolant temperature
• oil pressure
• oil temperature
• oil level
• crankcase pressure
• water in fuel
• fuel pressure
• coolant level
The data gives exact information about the operating conditions and
makes it possible for the control unit to, for example, calculate the cor-
rect fuel volume and to check the condition of the engine.

22 11 Common electrics – 11.5.3.10 Engine control unit (D794)
Engine control unit (D794), description (Cummins QSB6.7

page
–
engine)
engine function, fuel injection, etc.
communication to the gearbox, which is connected to the cab control
1 unit (D790-1). The cab control unit (D790-1) sends drivetrain informa-
tion on to other units.
2 play. All functions are controlled via the CAN bus and an external con-
trol system.
009746
3
formance.
1. Connector OEM
• engine rpm
2. Connector Actuator
3. Connector Sensor • boost pressure
• oil pressure
• oil temperature
• coolant level
• water in fuel
• air pressure

11 Common electrics – 11.5.3.10 Engine control unit (D794) 23
Engine control unit (D794), description (Cummins QSM11

page
–
engine)
1 2 3
engine function, fuel injection, etc.
communication to the gearbox, which is connected to the cab control
unit (D790-1). The cab control unit (D790-1) sends drivetrain informa-
tion on to other units.
play. All functions are controlled via the CAN bus and an external con-
trol system.
007423
formance.
1. Connector OEM
• engine rpm
2. Connector Actuator
3. Connector Sensor • boost pressure
• oil pressure
• oil temperature
• coolant level
• water in fuel
• air pressure
Engine control unit, replacement

page
–
See supplier documentation engine.
CAUTION
Each control unit is individually calibrated to the en-
gine in question. Switching of control units between
engines is absolutely forbidden.

24 11 Common electrics – 11.5.3.11 Control unit KIT (D790-2)
11.5.3.11 Control unit KIT (D790-2)

KIT control unit (D790-2), description
page
–
The KIT control unit (D790-2) handles functions for the gear selector
1 2
and multi-function lever, the direction indicator switch and start key po-
sitions II and III. It also handles the key panel (2) for the control system
and its panel for warning and indicator lights (1).
The KIT control unit (D790-2) has several individual function keys and
indicator lights (see illustration).
See the operator’s manual for detailed information on warning and in-
dicator lights and function keys.
000049
1. Panel, warning and indicator lights

2. Panel, keys
KIT control unit (D790-2), replacement

page
–

3 Detach the KIT control unit (D790-2) from the steering wheel pan-
el.
4 Detach the connector sockets.
5 Remove the warning panel for warning and indicator lights.
7 The KIT control unit (D790-2) is not calibrated.

11 Common electrics – 11.5.3.12 Control unit KID (D795) 25
11.5.3.12 Control unit KID (D795)

KID control unit (D795), description
page
–
The KID control unit (D795) displays to the operator information sent
1 2 by the control unit, such as speed, in the form of messages, status, er-
ror indications, etc.
There is an indicator light to the right of the display that is activated
with a red light when there is a serious malfunction in the control sys-
tem. The error code and information are shown on the display.
See the operator’s manual for detailed information on the display.
000051
1. LCD display
2. Series of diodes that constitute the indicator light for
a serious fault.
KID control unit (D795), replacement

page
–

3 Detach the connector from the KID control unit (D795).
4 Detach the KID control unit (D795) from the steering wheel panel.
6 The KID control unit (D795) is not calibrated.

26 11 Common electrics – 11.5.5 Cables
11.5.5 Cables
Connectors, overview
page
–
The list includes all connectors on the machine with a brief description
of their locations and to which functions the signals in them are related.
Connector Location Function

X001 Control unit cab (D790-1) Power supply and earth connection Control unit cab (D790-1)
X002 Control unit cab (D790-1) Front windscreen wiper

Heater fan
Actuator motor, recirculation
Windscreen wiper, rear
Motor, rotating beacon
Reversing light
X004 Control unit cab (D790-1) Water valve

Air distributor
Interior temperature sensor
Ambient temperature sensor
Temperature sensor, outlet fan
Sensor temperature refrigerant
Air conditioning sensor
Front windscreen wiper motor
X005 Control unit cab (D790-1) Switch, left panel

Switch option
Window washer, roof rear
Switch warning light (Hazard)
Setting fan speed
Setting temperature
Air distribution
Fan and recirculation controls
Accelerator pedal
Alignment bypass
X006 Control unit cab (D790-1) Instrument illumination

Switch work lights
Switch, rotating beacon
Switch, headlights
Switch option
Seat heater
Accelerator pedal
Release pedal

11 Common electrics – 11.5.5 Cables 27

X007 Control unit cab (D790-1) Control lever
Twistlock
Spreading
X008 Control unit cab (D790-1) Switch, levelling

Switch, spreading
Switch, bypass
Emergency stop switch
Switch, parking brake
Switch, reversible operator’s seat/cab tilt
Sensor twistlocks
Switch 30-35 stop
Switch, aut. 20-40
Switch option
Instrument illumination
Switch, electric servo panel
X009 Control unit cab (D790-1) Background illumination, switches

Lever steering or mini-wheel
Switch, horn
X009-2 Control unit cab (D790-1) Control lever
X010 Control unit cab (D790-1) Sensor alignment

Water valve
Horn
Relay, seat heating
Relay, work lighting
Hour counter
Relay, Compressor
Control current relay K315-1, K3009-1, K3009-2, K315-2, K3002 and
K3007
Front windscreen washing
Windscreen wiper, roof
X011 Control unit cab (D790-1) Ignition switch

Switches, cab doors
Switch, entry lighting
Interior lighting
Redundant feed, cab control unit (D790-1)
Horn
Switch, seat
Feedback relay K3009-1


X012 Control unit cab (D790-1) Windscreen wiper, rear
Windscreen wiper, roof
X013 Control unit cab (D790-1) CAN-bus

RS232
X015 Control unit KIT (D790-2) CAN-bus

Power supply and earth connection, Control unit KIT (D790-2)
X016 Control unit KIT (D790-2) Ignition switch
X017 Control unit KIT (D790-2) Switch, horn

Control, windscreen wipers
Control, gear
Control, main and dipped beams
X018 Control unit KIT (D790-2) Steering angle sensor

Buzzer
Switch, direction indicators
Switch interior lighting
X020 Control unit KID (D795) CAN-bus

RS232
Power supply and earth connection, Control unit KID (D795)
X033 Air conditioning system Control, fan

Control, temperature
Control, air distribution
Fan and recirculation controls
Instrument illumination
X034 Air conditioning system Heater fan

Water valve
X035 Air conditioning system Valve, air distribution

Interior temperature sensor
Temperature sensor, outlet fan
X036 Air conditioning system Actuator motor, recirculation

Sensor temperature refrigerant
X038 Instrument panel, cab Accelerator pedal

Release pedal


X039 Electrical distribution box cab Relay, Compressor, seat with air suspension
Switch, cab door
Actuator motor, recirculation
Fan motor, heating
Water valve, ECC
Air conditioning sensor
Ambient temperature sensor
X040 Electrical distribution box cab Alignment bypass

Window washer, roof/rear
Accelerator pedal
X048 Electrical distribution box cab Termination resistor
X049 Electrical distribution box cab Termination resistor
X050 Electrical distribution box cab RS232 Control unit cab (D790-1)
X051 Electrical distribution box cab Feedback relay K3009-1

Power supply, Control unit cab (D790-1)
CAN-bus
X052 Electrical distribution box cab CAN-bus

Control relays K315-1, K3009-1, K3009-2 and K315-2
X054 Electrical distribution box cab Interior lighting

Reversing light
Rotating beacon
X055 Electrical distribution box cab Windscreen wiper, roof

Current, CD player
Current, COM radio
X056 Electrical distribution box cab Rotating beacon

Working lights, cab
X057 Electrical distribution box cab Windscreen wiper, rear
X058 Electrical distribution box cab Motor, windscreen washers

Engine heater start inhibitor, bridged

Interior lighting


X060A Extension X060 CAN-bus
Interior lighting
X061 Electrical distribution box cab Earth connection, Control unit KID (D795)
Power supply, Control unit KIT (D790-2)
X061A Extension X061 Earth connection, Control unit KID (D795)

Power supply, Control unit KIT (D790-2)
X062 Electrical distribution box cab Horn

Compressed air horn
Map lighting
Cigarette lighter 12V
Windscreen wiper front
Heater fan motor
Actuator, recirculation
X063 Electrical distribution box cab Sensor operator in seat

Seat heater
Compressed-air damped seat
X065 Electrical distribution box cab Ambient temperature sensor
X066 Electrical distribution box cab Accelerator pedal

Interior lighting
X067 Electrical distribution box cab Customisation
X069 Electrical distribution box cab Sensor, twistlock open/closed

Twistlock relay
Spreading relay
X070 Electrical distribution box cab Bypass sensor

Sensor twistlocks
Spreading relay
X072 To Right Behind Seat Power outlet
X080 Instrument panel, cab Switch, mast/attachment work lights

Switch, main beams
Switch, rotating beacon
Switch, seat heater
Switch, option


X081 Instrument panel, cab Switch, option
Extra sensors
Hour counter
X082 Instrument panel, cab NC switch, cab doors
X090 Electric servo panel, cab Electric servo

Electric servo, lift/lower
Electric servo, tilt
Electric servo, side shift
Electric servo, spreading
Electric servo, auxiliary
X091 Electric servo panel, cab Horn

Switch, spreading
Switch, twistlock
Switch, levelling
X092 Electric servo panel, cab Switch, twistlock

Reversible operator's seat
X168 Electrical distribution box frame Power supply, frame control unit and attachment
X201 Electrical distribution box frame Earth connection and power supply, Control unit transmission (D793)
X202 Front edge of frame Twistlock solenoid valve

Spreading solenoid valve
Power supply and ground connection, attachment sensor
Sensor alignment
Sensor twistlocks
X203 Electrical distribution box frame Termination resistor
X204 Front edge of frame Mast work lights
X205 Electrical distribution box frame CAN-bus

Transmission control unit (D793)
X207 Front edge of frame Sensor alignment

Sensor twistlocks
X208 Left side, carriage Twistlock solenoid valve

Spreading solenoid valve
Power supply and ground connection, attachment sensor
Sensor alignment
Sensor twistlocks


X209 Front edge of frame Power supply, cab control unit (D790-1)
CAN bus, frame control unit (D797-1)
CAN bus, frame option control unit (D797-2)
X210 Between engine and gearbox Power supply and earth connection, Control unit engine (D794)
CAN bus, Control unit engine (D794)
X211 Frame control unit (D797-1) 42-pin connector to frame control unit (D797-1)
X212 Frame control unit (D797-1) Power supply and ground connection, frame control unit (D797-1)
CAN bus, frame control unit (D797-1)
Temperature hydraulic oil
Emergency stop switch voltage
Sensor, fuel level
D+ alternator
X214 Front edge of frame CAN bus, frame option control unit (D797-2)
X215 Electrical distribution box frame Power supply attachment control unit
X221 Frame option control unit (D797-2) 42-pin connector to frame option control unit (D797-2)
X222 Frame option control unit (D797-2) Power supply and ground connection, frame option control unit (D797-2)
CAN bus, frame option control unit (D797-2)
Emergency stop switch voltage
X230 Beneath operator’s seat Sensor operator in seat
X235 Front edge of frame Lift/lower valve

Tilt valve
Mast valves
X240 Front edge of frame Power supply
X241 Front edge of frame Option
X242 Front edge of frame Option
X243 Front edge of frame Low beam rear

High beam rear
Tail light front
Switch, reversible operator’s seat
Control valve, reversible operator’s seat
Directional control valve, steering forward/rearward
X244 Front edge of frame Side shift valve

Spreading valve
Control valve load handling
Control valve, mini-wheel/lever steering


X245 Under cab Switch, reversible operator’s seat
Position sensor, reversible operator’s seat
X247 Front edge of frame Brake light forward
X248 Front edge of frame Mast position sensor

Position sensor, automatic cab tilt
X251 Control unit transmission (D793), 30-pin connector for Transmission control unit (D793)
electrical distribution box frame
X252 Control unit transmission (D793), 18-pin connector for Transmission control unit (D793)
electrical distribution box frame
X253 Gearbox Solenoid valves, transmission

Pressure sensor, transmission
X259 Gearbox Temperature sensor, transmission oil for radiator
X261 Electrical distribution box frame RS232 Control unit transmission (D793)
X264 Electrical distribution box frame Solenoid valve brake transmission
X270 Lamp bracket left front Main and dipped beams

Driving direction indicator
Side marker lights
X271 Lamp bracket front Main and dipped beams

Side marker lights
X272 Lamp bracket left rear Tail light

Brake light
Side marker lights
X273 Lamp bracket right rear Tail light

Brake light
Side marker lights
X275 Rear edge of frame Tail light

Brake light
Side marker lights
Reversing alarm
X276 Under cab Entry lighting

X278 Between engine and gearbox Compressor air conditioning

Relay, start key


X279 Engine control unit (D794) Power supply and earth connection, Control unit engine (D794)
CAN-bus Drivetrain
X280 Engine Coolant level
X301 Mast Mast position sensor
X302 Mast Position sensor, automatic cab tilt
X403A Attachment centre Sensor, abutment right side

Sensor, twistlocks right side
X403B Attachment, right side Sensor, abutment right side

Sensor, twistlocks right side
X404 Attachment centre Sensor, abutment left side

Sensor, twistlocks left side
Sensor, damping 20-40
Sensor, stop 30-35
X405 Attachment, right side Indicator light locked twistlocks

Indicator light, unlocked twistlocks
Indicator light alignment
X428 Cab Rotating beacon
X612 Air conditioning system Actuator motor, recirculation
X645 Engine Compressor air conditioning
X651 Cab Motor, windscreen washers
X657 Cab Heater fan
X660 Engine Alternator
X690 Cab Accelerator pedal
X759 Engine Coolant level
X774 Cab Ambient temperature
X775 Cab Temperature sensor, cab, fan, refrigerant
X815 Cab Power assisted system
X825 Cab Mini-wheel
X900 Cab CD player
X901 Voltage converter, cab Voltage converter 24 V/12 V

Socket 24 V

Signal types, general

page
–
The machine’s control units use a number of different types of signals

to receive signals from sensors and switches and control solenoid
valves, lights, etc. The table below describes the different signal types.
Signal type Explanation Usage area
Analogue inputs
Rheostat Resistance input 0–200 Ω. Linear work range with accuracy of 3%. E.g. fuel level sensor.
Temperature Rheostat input with non-linear work area. The resistance value is equiva- E.g. hydraulic oil temper-
lent to temperature and the work range of approx. -40 to 150 °C. ature sensor and climate
There are two different resistance curves - one for the cab control unit control system tempera-
(D790-1) and one for the frame and attachment control units. ture sensor.
Accuracy is ±0.5 °C in the interval 0 –100 °C (sensor’s measurement in-

accuracy not included). Outside of the interval 0 –100 °C, accuracy is
±2 °C.
Voltage An analogue signal 0–5 V. The work range is 0.5 to 4.5 V. E.g. accelerator pedal
and analogue cab con-
trols (operating lever and
heater controls).
Analogue outputs
Current feedback A modulated signal between 0 V and system voltage, i.e. 24 V. The work Hydraulics, e.g. lifting/
voltage out, PWM range is 0 to 2 A. lowering of the boom.
A modulated signal is a digital signal translated to an analogue (continu- Used when the output
ous) signal adapted for a purpose, such as solenoid valve control. signal actuates propor-
When the spool in a solenoid valve gets hot, resistance drops. This gen- tional solenoid valves.
erates a lower current through the valve spool, which can cause the
valve’s servo pressure to remain constant. An internal ampermeter meas-
ures current in the circuit and regulates the voltage level in order to main-
tain the desired current value in the valve spool.
Voltage out, PNP A modulated signal between 0 V and system voltage, i.e. 24 V. Requires E.g. interior lighting and
PWM a grounding point as reference. background illumination
in switches.
Voltage out, re- A modulated signal between 0 V and system voltage, i.e. 24 V. Requires E.g. cab fan.
versed polarity, 24 V as reference.
NPN PWM
Digital inputs
Digital input signal Signal in, U < 5 V generates logic zero (0) E.g. input signal from a
with pull down and Signal in, U > 16 V generates logic one (1) breaker with search light-
search lighting ing.
If there is no signal in, the input is grounded.
Digital input signal Signal in, U < 5 V generates logic zero (0) E.g. position sensors (in-
with pull down Signal in, U > 12 V generates logic one (1) ductive sensors) and
brake pressure (pressure
If there is no signal in, the input is grounded. switches).
Bandwidth 300 Hz, i.e. designed for slow sensors.

Signal type Explanation Usage area
Digital outputs
High side driver, Logic one (1) generates voltage out, U >= 22.5 V E.g. side marker lights,
1.5 A Max. load 1.5 A solenoid valves.
Open load 0.15 A

Max. instantaneous current load, 8 A
High side driver, Logic one (1) generates voltage out, U >= 22.5 V E.g. work lighting and
5A Max. load 5 A wiper motors.
Open load 0.9 A

High side driver, Logic one (1) generates voltage out, U >= 22.5 V E.g. cooling fan.
10 A Max. load 10 A This output is only found
Open load 1.9 A on the frame and attach-
ment control units.
H-bridge Logic one (1) generates voltage out, U >= 22.5 V or grounded output, E.g. climate control sys-
U=0V tem water valve (works in
Max. load 0.5 A both directions).
Open load 0.15 A

The H-bridge works with two outputs in a pair. At logic one (1), one output
gives voltage while the other output is grounded. At logic zero (0), the out-
puts switch voltage levels.

11 Common electrics – 11.6 Communication 37
11.6 Communication
11.6.1 CAN-bus
CAN bus, description
page
–
Communication between the control units takes place using so-called

1 2
"CAN buses" (Controller Area Network) based on the ISO 11898
standard and CAN specification 2.0B.
The CAN bus is a fast control bus with logical hardware circuits. A sim-
120 ohm 120 ohm
ple technology that is highly reliable (low error frequency), which is a
requirement for control signals to be able to regulate systems based
on varying conditions and requirements.
CAN specifies:
5 5
• that the signal traffic is carried by "twisted pair" cables
3
4 • that termination resistors (position 1) are necessary (adapted to
2 cables’ impedance) so that the pulse train (position 4) can obtain
U [V]
a sharp signal.
• that the signal valve is given as the potential difference between
3 the cables, CAN + and CAN - (position 2 and 3).
000026
t [S]
• form of signal messages.
Messages run in time and signal goes high (voltage
high) or low (voltage low).
1. Termination resistor (120 ohm)
2. CAN + (voltage high)
3. CAN - (voltage low)
4. Pulse
5. Control unit
Message
There are two types of messages:
A
• CAN Standard, has identity field of 11 bits
• CAN Extended, has identity field of 29 bits
B C D E F G CAN works in messages sent in frames of 8 bytes (64 bits). A com-

000027
plete message is approx. 100 bits long. The illustration depicts how a
t [S]
message is structured.
Messages run in time and signal goes high (voltage
high) or low (voltage low). Start bit (B)
A. Length message Indicates that the transmission of a frame, i.e. a message, is now be-
B. Start bit ginning.
C. Identity field/Priority Identity field (C)
D. Control field (length of data segment)
Indicates what kind of information the message contains, e.g. meas-
E. Data segment
urement information on engine speed.
F. Checksum for error detection
G. Acknowledge bit Does not indicate address to control unit. CAN does not work with ad-
dressing. All control units receive messages and send them on.

38 11 Common electrics – 11.6.1 CAN-bus
Control field (D)

Indicates how the length of the data segment that follows.
Data segment (E)
Contains the information to be conveyed to control units in the net-
work.
Checksum for error detection (F)
Calculates a checksum for the message. This makes it possible for the
receiving control unit to detect errors in the sent message.
Acknowledge (G)
The transmitting control unit sets a bit to logic one (1) when the mes-
sage is sent. The first control unit to receive the message sends it on
and sets the bit to logic zero (0).
Communication
The CAN network consists of control units and segment. The segment
(bus) is a twisted pair cable that leads CAN + and CAN - signal levels
from control unit to control unit.
Each control unit measures the potential difference of its two inputs.
3,5 V The potential difference generates logic zero and logic one. The illus-
tration depicts an approved interval according to the standard for po-
tential levels. CAN + has a recommended value of 3.5 V and CAN -
U [V]
has 1.5 V. As a worst case scenario, the potential difference can be

0,5 V 0.5 V and still be approved. In practice, a potential difference of 2 V is
recommended for reliable communication.
Pulse trains can only be observed using an oscilloscope, NOT with a
1,5 V digital multimeter.
When a message is sent, all control units in the network listen. Mes-
sages are saved in the control unit and relevant information is proc-
essed. The control unit that receives the message first confirms
000028
t [S] receipt (sets an acknowledge bit). The transmitting control unit then
knows that the message has been received by at least one control
Potential levels CAN + and CAN -
unit.
One control unit at a time sends the message. Other control units lis-
ten and wait until the bus is available. If two messages are to be sent
simultaneously then the sending of the message with the lowest prior-
ity (highest value in identity field) is concluded. This means that mes-
sages do not need to be re-sent in the event of a communication
conflict but only in the event of a bus error (erroneous message).
The CAN bus exchanges around 100 messages per second in the net-
work.
Different bus systems can be used e.g. random sending or primary
(master) / secondary (slave),

11 Common electrics – 11.6.2 Redundant CAN bus 39
HLP High Layer Protocol

CAN only specifies messages and how communication shall take
place, i.e. one protocol. In order to manage the network the CAN pro-
tocol needs to be supplemented by a HLP which specifies:
• flow control
• transport of data above a length of 8 bits in 8 bit messages (divi-
sion)
• how control units are addressed in the network
• how bits in the message's data field shall be interpreted
11.6.2 Redundant CAN bus

Redundant CAN bus, description
page
–
The redundant CAN bus handles communication between all of the

D790-1 D790-2 D795 machine’s control units except the transmission control unit (D793)
CAN R CAN L CAN R CAN L
and the engine control unit (D794). These have a separate CAN bus;
see Drivetrain CAN bus, description page 41.
CAN L CAN R CAN L CAN R

009747
D797-2 D797-1
Principle illustration, redundant CAN bus

Redundant CAN bus means that the control units are connected to a
D790-1 D797-1 network that communicates via a CAN bus (see CAN bus, description
CAN L CAN R CAN L CAN R
page 37) and that there are double communication routes on the net-
1 work. The network is divided into control units and segments (seg-
3 ments are cables between the control units). The number of active
2
CAN R CAN L
segments depends on the number of control units the machine has,
which depends on the machine’s equipment level (options).
009748
D795
Segment numbering starts from the CAN-R (right)

connection
The network is built on the CAN kingdom principle, which means that
D790-1 D797-2 D797-1 one control unit is central and is the master unit. In this case, it is the
CAN L CAN R CAN L CAN R CAN L CAN R
cab control unit (D790-1). Other control units in the network are sec-
1 2 ondary (slaves) and handle special areas, e.g. machine components.
4
3 The control units have two CAN bus connections - CAN L (left) and
CAN R CAN L
CAN R (right). The control units are connected to one another in series
009749
D795 in a loop.
The redundant CAN bus can handle the loss of a segment. The link is
Segment numbering with optional equipment
analysed upon start-up. If a segment is faulty, messages are sent via
another route.
If several segments are lost, one or more control units lose communi-
cation and work independently, often with significantly limited function-
ality.
CAN bus faults are indicated with an error code and a warning in the
display. If several CAN bus segments are faulty, the system only
shows an error code for the first faulty out segment.

40 11 Common electrics – 11.6.2 Redundant CAN bus
Connection of redundant CAN bus
Condition Reference Reference

value
Battery disconnect switch In position 1 Battery disconnect switch, description page 3
Redundant voltage feed Activated Redundant voltage feed for control units, description of operation page 7
S1 D790-1 S4 D795 S3
1, 6 4
D790-2
5
2 3
009753
D797-2 S2 D797-1

1 The cab control unit (D790-1) establish- Checked by control sys- Cab control unit (D790-1), description page
es redundant CAN bus communication tem, error shown with er- 17
by sending a request on the CAN bus ror code. Diagnostic menu, see section 8 Control sys-
via CAN R. tem, group 8.4.1.1 CAN/POWER, menu 1
and 8.4.1.2 CAN/POWER, menu 2
2 The frame control unit (D797-2) sends a A clicking sound is audi- Frame control unit (D797-2), description
response back on the CAN bus via CAN ble when then termina- page 19
L and sends the request on via CAN R. tion resistor is activated. Diagnostic menu, see section 8 Control sys-
Termination resistors in the control tem, group 8.4.1.1 CAN/POWER, menu 1
nodes ensure communication segment and 8.4.1.2 CAN/POWER, menu 2
by segment.
3 The frame control unit (D797-1) sends a A clicking sound is audi- Frame control unit (D797-1), description
response back on the CAN bus via CAN ble when then termina- page 18
L and sends the request on via CAN R. tion resistor is activated. Diagnostic menu, see section 8 Control sys-
Termination resistors in the control tem, group 8.4.1.1 CAN/POWER, menu 1
nodes ensure communication segment and 8.4.1.2 CAN/POWER, menu 2
by segment.
4 The KID control unit (D795) sends a re- A clicking sound is audi- KID control unit (D795), description page 25
sponse back on the CAN bus via CAN L ble when then termina- Diagnostic menu, see section 8 Control sys-
and sends the request on via CAN R. tion resistor is activated. tem, group 8.4.1.1 CAN/POWER, menu 1
Termination resistors in the control and 8.4.1.2 CAN/POWER, menu 2
nodes ensure communication segment
by segment.
5 The KIT control unit (D790-2) is not con- A clicking sound is audi- KIT control unit (D790-2), description page
nected to the redundant CAN bus. The ble when then termina- 24
KIT control unit (D790-2) does not com- tion resistor is activated.
municate until ignition voltage (15) is ac-
tivated.

11 Common electrics – 11.6.3 CAN bus drivetrain 41

6 If a control unit has not responded, the Checked by control sys- Diagnostic menu, see section 8 Control sys-
cab control unit (D790-1) uses both tem, error shown with er- tem, group 8.4.1.1 CAN/POWER, menu 1
CAN L and CAN R to keep communica- ror code. and 8.4.1.2 CAN/POWER, menu 2
tion open and analyses which segment
is faulty.
11.6.3 CAN bus drivetrain

Drivetrain CAN bus, description
page
–
The drivetrain CAN bus is based on the SAE J1939 standard where
4 6
selected messages are used to control engine and transmission.
SAE J1939 is a standard from SAE (Society of Automotive Engineers)
for data communication in vehicles. The standard regulates hardware
interface, bit times and message composition.
D790-1 3 5
The engine and transmission control units come from the respective
engine and transmission suppliers.
The machine can be equipped with different models of gearboxes and
engines. The messages from the engine and gearbox are based on
the standard’s structure.
Communication with engine control unit (D794) and transmission con-
trol unit (D793) are separate from the redundant CAN bus.
The signals can be checked from the diagnostic menu, see section 8
Control system, group 8.4.1.4 CAN/POWER, menu 4.
000033
1 2
1. Redundant CAN bus
2. CAN bus drivetrain
3. Engine control unit (D794)
4. Engine
5. Transmission control unit (D793)
6. Gear box

42 11 Common electrics – 11.6.4 Communication between PC and machine
11.6.4 Communication between PC and

machine
Communication between PC and machine,
page
–
description
The machine has three or four sockets for communication between
control units and PC. Two are located in electrical distribution cab and
1 one or two in electrical distribution cab frame. It is the socket for com-
munication with engine alternative Volvo that varies.
2 The socket for programming control units in cab electrical distribution
box (position 1) is used to program the control units in the cab and on
the frame.
The socket for CAN bus drivetrain in the cab electrical distribution box
(position 2) is used for communicating with the engine and transmis-
sion via CAN bus.
The VODIA socket in the frame electrical distribution box (position 3)
(VOlvo engine only) is used to connect the Volvo’s diagnostic tool -
VODIA.
The socket for transmission control unit (D793) programming in the
frame electrical distribution box (position 4) is used to program the
For further details on communication between computer and machine,
contact Kalmar Industries AB.
3
4
010116
1. Diagnostic socket, machine

2. Diagnostic socket, CAN bus drivetrain (Cummins
engine)
3. Diagnostic socket, engine, VODIA (Volvo engine)
4. Diagnostic socket, transmission

11 Common electrics – 11.6.5 RMI (Remote Machine Interface) 43
11.6.5 RMI (Remote Machine Interface)

RMI (Remote Machine Interface), description
page
–
Remote Machine Interface is a tool for listening to the machine at a

distance. The interface consists of a control unit which is connected to
007443
the machine, antenna for communication and GPS-antenna ( ) for
positioning.
RMI-interface
The interface records the communication on the CAN-bus and sends
the information to a central RMI-server. The control unit in the machine
can sends the information via GSM, GPRS, WLAN, Radio-modem,
SMS, or e-mail in case of a malfunction.
From the RMI-server, data from the machine can be analysed and
processed to read out different values. For example, when it is time for
service or if there are error codes stored in the machine.
As an option, there is a GPS-antenna, making it possible to read

off the machine’s position.
NOTE
RMI only sends data from the machine, no data can be sent to
the machine. RMI cannot be used to control the machine.

44 11 Common electrics – 11.6.5 RMI (Remote Machine Interface)

D Error codes 1
D Error codes
Table of Contents D Error codes

mm mm mm mm mm mm
Error codes ..................................................................................................... 3

Error codes, explanation ........................................................................................ 3
Error code menu, description ................................................................................. 4
Reading out error code ........................................................................................... 7
1 Engine ............................................................................................................. 9
Error codes engine, general ................................................................................... 9
Felkoder motor (motoralternativ Cummins QSB6.7) ............................................ 10
Error codes (Cummins QSM 11 engine) .............................................................. 33
Error codes engine (engine alternative Volvo TAD760VE) .................................. 45
Error codes (Volvo TAD950VE and TAD952VE engines) .................................... 58
Error codes (Volvo TAD1250VE engine) .............................................................. 74
2 Transmission................................................................................................ 87
Error codes, transmission ..................................................................................... 87
8 Control system ............................................................................................. 96
Error codes machine ............................................................................................ 96

2 D Error codes

D Error codes – Error codes 3
Error codes
mm mm mm mm mm mm
Error codes, explanation

page
–
The error codes are explained in table form for Engine, Transmission
as well as Control system. They are sorted according to error code
number.
The error code table has the following information:
• Code, error code's number, shown in field C on display.
C
• Description, explanation of the error code and when it's generat-
D E ed.
• Limitation, in case of certain error codes certain functions are im-
B
000389
paired or limited to protect the machine and operator.

• Action, information of what should be checked to find the cause of
B. Error code level (symbol)
the error code.
C. Error code number
D. Cause of error (symbol) • Diagnostic menu, reference to suitable diagnostic menu to fix the
E. Function (symbol) problem, read signal value or check the function.
In addition to the explanation of the display figure, the description
of the diagnostic menus contains reference to circuit diagrams
that are found in section E Schematics and reference to function
group for further information about functions and components.
• Function group is a reference to which function group the error
code is connected. This field is used to search for more informa-
tion as necessary. The function group can be used to find different
types of information.
Sections 0-12 contain a description of the function and its compo-
nents, component position and work instructions for different
work.

4 D Error codes – Error codes
Error code menu, description

page
–
The control system’s display is divided into four fields that show infor-
C mation (see figure to the left).
D E • Field B: Error code level shown with a symbol.

• Field C: Indicates error code.
B
000389
• Field D: Indicates type of error.
• Field E: Indicates which function is affected by error code.
• The book symbol means that there's information in the operator's
manual.
Field B: Error code level

The control system gives error code information in three levels which
are indicated with a symbol in the lower left corner (B) on the display
unit.
• Stop
C Indicates a serious malfunction that may affect operator safety or
cause machine breakdown. The error code must be taken care of
D E
immediately. Stop working with the machine and contact service
immediately.
000350
• Warning
C Indicates machine malfunction that should be taken care of as
soon as possible. After finished work shift with the machine, con-
D E
tact service as soon as possible.
000351
• Information
C Information to the operator that something should be fixed, e.g.,
broken bulb. Fix the cause of the error code as soon as possible.
D E See section 6 Inspection and maintenance in the Operator’s man-
ual.
000352
The error code is stored in the error code list under operating
menu for service.

Field C: Error code number

The control system gives error codes from three sub-systems:
• Machine:
C
Shown with error code number XXX on display.
D E
000389
• Engine:
C Shown with error code number XXX/YY on display.
D
NOTE
B If several error codes come from the engine, the error code
001343
level is shown for the most serious error code.
• Transmission:
C Shown with error code number XX/YY on display.
B
001344
Field D: Type of error

1. Too high/too low temperature.
1 2 3
2. Incorrect signal to solenoid valve.
3. Incorrect hydraulic pressure.
4. Incorrect sensor signal.
4 5 6 5. Incorrect signal from control.

6. Incorrect signal to bulb.
7. Incorrect signal, for example, open circuit.
7
000396

Field E: Affected function

1. Attachment
1 2 3
2. Rotation of attachment
3. Side shift of attachment
4. Length adjustment attachment
4 5 6
5. Leveling attachment
6. Twistlocks
7. Forks up/down
7 8 9 8. Tilt forks
9. Side shift forks
10. Spreading forks
10 11 12 11. Rotation forks

12. Overload protection
13. Hydraulic functions
14. Brake system
13 14 15
15. Steering
16. Engine
17. Transmission
16 17 18
18. Central lubrication
19. Control unit
20. Hardware-related error
19 20 21 21. Cab
22. Air conditioning system
23. Fuel system
22 23 24 24. Headlights
25. Windshield wipers
26. Battery voltage
25 26 27 27. Bulb for lighting
010153

Reading out error code

page
–
NOTE
In case of an error code, perform the actions recommended in the
error code table to find the problem.
Error codes are stored as active and inactive. Active errors are
shown in the error code menu.
Always use error code menus for reading out error codes, other-
wise there is a risk of missing error codes.
1 Turn the start key to position I.
WARNING
Risk of machine damage.
In case of error codes of level “WARNING” and

“STOP”, serious machine damage may result if the
engine is started.
Do not start the engine until the cause of the error

code has been identified or repaired.
2 Navigate to the service menu and press Enter.

000056
3 Safety menu is shown. Hold Enter depressed for at least two sec-
onds.
1 23
4 5
000060
4 The error code list is shown on the display. Active error code is
shown on display where field C shows error code number togeth-
er with X(Y). X shows sequence number for shown error code
and (Y) shows number of active error codes.
Scroll between error codes with key 1 and 2 (arrow function).
001998
Error codes disappear from the list when the cause has been
remedied.

5 Note error code number (field C) to not forget.

C
• Error code level is shown with a symbol in field B
D E • Error code is shown in field C
B • Error cause is shown with a symbol in field D
000389
• Function affected by the error is shown with a symbol in field
E
The book symbol is an instruction for the operator to read the
operator’s manual.
6 Use the error code tables to find more information about the error
code.
7 After action, check that no active error codes remain for the func-
tion in question.

D Error codes – 1 Engine 9
1 Engine
mm mm mm mm mm mm
Error codes engine, general

page
–
When contacting engine suppliers, use Volvo/Cummins codes.

• The display shows error codes as specified in SAE J1939 SPN /
FMI.
• Flash indicates error code according to a flash code specified by
the engine supplier.
• J1587 indicates error code according to SAE J1587 (for Volvo:
Vodia)
PID, PPID, SID, PSID / FMI.
Table 1. Specification FMI
FMI Description SAE-text

0 Too high value. Valid data, but higher than normal operating range.
1 Too low value. Valid data, but lower than normal operating range.
2 Incorrect data. Intermittent or incorrect data.
3 Electrical problem. Abnormally high voltage or short-circuiting to higher voltage.
4 Electrical problem. Abnormally low voltage or short-circuiting to lower voltage.
5 Electrical problem. Abnormally low current or open circuit.
6 Electrical problem. Abnormally high current or short-circuiting to frame ground.
7 Mechanical problem. Incorrect response from mechanical system.
8 Mechanical problem or electrical prob- Abnormal frequency.
lem.
9 Communication error. Abnormal update rate.
10 Mechanical problem or electrical prob- Abnormally wide variations.
lem.
11 Unknown malfunction. Non-identifiable error.
12 Component error. Defective unit or component.
13 Incorrect calibration. Values outside calibration values.
14 Unknown malfunction. Special instructions.
15 Too high value. Data valid but above normal operating range - Least severe level.
16 Too high value. Data valid but above normal operating range - Moderately severe level.
17 Too low value. Data valid but below normal operating range - Least severe level.
18 Too low value. Data valid but below normal operating range - Moderately severe level.
19 Communication error. Received network data in error.
20-30 Reserved for SAE assignment.
31 FMI is not available or the condition that Not available or condition exists.
is identified by the SPN exists.

10 D Error codes – 1 Engine
Felkoder motor (motoralternativ

page
–
Cummins QSB6.7)
Description Limitation Action Connec- Diagnos-
tions and tic menu
compo-
nents
Code J1587
84 / 2 P084 / 2 Machine Speed Sensor Cir- Engine speed limited Check cabling D794 ENGINE,
cuit - Data Erratic, Intermittent to Maximum Engine between control menu 2
or Incorrect. The ECU 794 lost Speed without VSS unit and compo-
the machine speed signal. parameter value. nent.
Cruise control, Gear- Check the sen-
Down Protection, and sor.
Road Speed Gover-
nor will not work.
84 / 10 P084 / 10 Machine Speed Sensor Cir- Engine speed limited Check cabling D794 ENGINE,
cuit Tampering Has Been De- to Maximum Engine between control menu 2
tected - Abnormal Rate of Speed without VSS unit and compo-
Change. Invalid or inappropri- parameter value. nent.
ate machine speed signal. Cruise control, Gear- Check the sen-
Signal indicates an intermit- Down Protection, and sor.
tent connection or VSS tam- Road Speed Gover-
pering. nor will not work.
91 / 0 P91 / 0 Accelerator Pedal or Lever Severe derate in - - ENGINE,

Position Sensor 1 - Data Valid power output of the menu 1
but Above Normal Operation- engine. Limp home
al Range - Most Severe Level. power only.
A frequency of more than
1500 Hz has been detected at
the frequency throttle input to
the ECU 794.
91 / 1 P91 / 1 Accelerator Pedal or Lever Severe derate in - - ENGINE,

Position 1 Sensor Circuit Fre- power output of the menu 1
quency - Data Valid but Below engine. Limp home
Normal Operational Range - power only.
Most Severe Level. A fre-
quency of less than 100 HZ
has been detected at the fre-
quency throttle input to the
ECU 794.
91 / 19 P91 SAE J1939 Multiplexing Ac- Engine may only idle Use diagnostic - -
celerator Pedal or Lever Sen- or engine will not ac- menu to find in-
sor System Error - Received celerate to full speed. correct segment.
Network Data Error. The OEM
machine electronic control
unit (VECU) detected a fault
with its accelerator pedal.


tions and tic menu
compo-
nents
Code J1587
91 / 2 P31 / 2 Accelerator pedal position - - ENGINE,
sensor. menu 1
91 / 3 P091 / 3 Accelerator Pedal or Lever Severe derate in Check cabling - ENGINE,

Position Sensor Circuit - power output of the between control menu 1
Shorted High. High voltage engine. Limp home unit and compo-
detected at accelerator pedal capability only. nent.
or lever position circuit. Check the com-
ponent.
91 / 4 P091 / 4 Accelerator Pedal or Lever Severe derate in Check cabling - ENGINE,

Position Sensor Circuit - Volt- power output of the between control menu 1
age Below Normal or Shorted engine. Limp home unit and compo-
to Low Source. Low voltage capability only. nent.
detected at accelerator pedal Check the com-
or lever position signal circuit. ponent.
94 / 1 P94 / 1 Fuel pump delivery pressure - Possibly hard to start; - D794 -

data valid but below normal low power; possible
operational range - moderate- engine smoke. En-
ly severe level. The ECU 794 gine can possibly not
has detected the fuel pressure start.
in the fuel rail is lower than the
commanded performance.
94 / 2 P094 / 2 Injector Metering Rail 1 Pres- The ECU 794 will es- - D794 -
sure - Data Erratic, Intermit- timate fuel pressure,
tent, or Incorrect. The ECU and power is re-
794 has detected that the fuel duced.
pressure signal is not chang-
ing.
94 / 18 P94 / 0 Fuel pump delivery pressure - None or possible en- - D794 -

data valid but above normal gine noise associated
operational range - moderate- with higher injection
ly severe level. The ECU 794 pressures (especial-
has detected fuel pressure in ly at idle or light load).
the fuel rail that is higher than Engine power is re-
the commanded pressure.. duced.
97 / 3 P097 / 3 Water-in-fuel indicator sensor None on perform- Check cabling D794 -

circuit - Voltage above normal ance. No water-in- between control
or short circuited to high fuel warning availa- unit and compo-
source. High voltage detected ble. nent.
at the water-in-fuel circuit. Check the sen-
sor.


tions and tic menu
compo-
nents
Code J1587
97 / 4 P097 / 4 Water-in-fuel indicator sensor None on perform- Check cabling D794 -
circuit - Voltage below normal ance. No water-in- between control
or short circuited to low fuel warning availa- unit and compo-
source. Low voltage detected ble. nent.
at the water-in-fuel circuit. Check the sen-
sor.
97 / 15 P097 / 0 Water-in-fuel indicator - Data Possible white Drain water from - -

valid but above normal opera- smoke, loss of power, the fuel.
tional range - least severe lev- or hard starting
el. Water has been detected
in the fuel filter.
100 / 1 P100 / 1 Engine Oil Rifle Pressure - Progressive power Check oil level in - ENGINE,
Data Valid but Below Normal derate increasing in the engine, top menu 6
Operational Range - Most Se- severity from time af- up as needed.
vere Level. Oil pressure signal ter alert. If the Engine
indicates oil pressure is below Protection Shutdown
the engine protection critical feature is enabled,
limit. engine will shut down
30 seconds after the
red STOP lamp starts
flashing.
100 / 2 P100 / 2 Oil Pressure Switch Sensor None on perform- Check cabling D794 ENGINE,
Circuit - Data Erratic, Intermit- ance. No engine pro- between control menu 6
tent or Incorrect. An error in tection for oil unit and compo-
the engine oil pressure switch pressure. nent.
signal was detected by the Check the sen-
ECU 794. sor.
100 / 3 P100 / 3 Oil Pressure Sensor Circuit - None on perform- Check cabling D794 ENGINE,
Voltage Above Normal, or ance. No engine pro- between control menu 6
Shorted to High Source. High tection for oil unit and compo-
signal voltage detected at the pressure. nent.
engine oil pressure circuit. Check the sen-
sor.
100 / 4 P100 / 4 Oil Pressure Sensor Circuit - None on perform- Check cabling D794 ENGINE,
Voltage Below Normal, or ance. No engine pro- between control menu 6
Shorted to Low Source. Low tection for oil unit and compo-
signal voltage detected at the pressure. nent.
engine oil pressure circuit. Check the sen-
sor.


tions and tic menu
compo-
nents
Code J1587
100 / 18 P100 / 1 Engine Oil Rifle Pressure - None on perform- Check oil level in - ENGINE,
Data Valid but Below Normal ance. the engine, top menu 6
Operational Range - Moder- up as needed.
ately Severe Level. Engine oil
pressure signal indicates en-
gine oil pressure is below the
engine protection warning lim-
it.
102 / 2 P102 /2 Intake Manifold Pressure Engine power derate. Check cabling D794 ENGINE,
Sensor Circuit - Data Erratic, between control menu 6
Intermittent or Incorrect. The unit and compo-
ECU 794 has detected an in- nent.
take manifold pressure signal Check the sen-
that is too high or low for cur- sor.
rent engine operating condi-
tions.
102 / 2 P102 /2 Intake manifold pressure sen- Derate in power out- Check cabling D794 ENGINE,
sor circuit - data incorrect. An put of the engine. between control menu 6
error in the intake manifold unit and compo-
pressure sensor signal was nent.
detected by the ECU 794. Check the sen-
sor.
102 / 3 P102 / 3 Intake Manifold Pressure Derate in power out- Check cabling D794 ENGINE,
Sensor Circuit - Voltage put of the engine. between control menu 6
Above Normal or Shorted to unit and compo-
High Source. High signal volt- nent.
age detected at the intake Check the sen-
manifold pressure circuit. sor.
102 / 4 P102 / 4 Intake Manifold Pressure Derate in power out- Check cabling D794 ENGINE,
Sensor Circuit - Voltage Be- put of the engine. between control menu 6
low Normal or Shorted to Low unit and compo-
Source. Low signal voltage nent.
detected at the intake mani- Check the sen-
fold pressure circuit. sor.
103 / 10 P103 / 10 Turbocharger speed - invalid Possible-low-power Check cabling D794 -

rate of change detected. The estimated turbo- between control
turbocharger speed sensor charger speed will be unit and compo-
has detected an erroneous used. nent.
speed value. Check the sen-
sor.


tions and tic menu
compo-
nents
Code J1587
103 / 16 P103 / 0 Turbocharger Number 1 Engine power derate. Check the com- D794 -
speed high - warning level. The ECU 794 uses ponent.
High turbocharger speed has an estimated turbo-
been detected. charger speed.
103 / 18 P103 / 1 Turbocharger number 1 Engine power derate. Check the com- D794 -
speed low - warning level. The ECU 794 uses ponent.
Low turbocharger speed de- an estimated turbo-
tected by the ECU 794. charger speed.
105 / 0 P105 / 0 Intake Manifold 1 Tempera- Progressive power Check the cool- - ENGINE,
ture - Data Valid but Above derate increasing in ant level in the menu 7
Normal Operational Range - severity from time af- engine, top up
Most Severe Level. Intake ter alert. If the Engine as needed.
manifold air temperature sig- Protection Shutdown Check that the
nal indicates intake manifold feature is enabled, charge-air cooler
air temperature above engine engine will shut down is clean, clean
protection critical limit. 30 seconds after the as needed.
Check that fan
flashing.
belts are intact.
Check the sen-
sor.
105 / 3 P105 / 3 Intake Manifold Air Tempera- Possible white Check cabling D794 ENGINE,
ture Sensor Circuit - Voltage smoke. Fan will stay between control menu 7
Above Normal or Shorted to ON if controlled by unit and compo-
High Source. High signal volt- the ECU 794. No en- nent.
age detected at intake mani- gine protection for in- Check the sen-
fold air temperature circuit. take manifold air sor.
temperature
105 / 4 P105 / 4 Intake Manifold Air Tempera- Possible white Check cabling D794 ENGINE,
ture Sensor Circuit - Voltage smoke. Fan will stay between control menu 7
Below Normal or Shorted to ON if controlled by unit and compo-
Low Source. Low signal volt- the ECU 794. No en- nent.
age detected at intake mani- gine protection for in- Check the sen-
fold air temperature circuit. take manifold air sor.
temperature


tions and tic menu
compo-
nents
Code J1587
105 / 15 P105 / 0 Intake Manifold Temperature Progressive power Check the cool- D794 ENGINE,
High - Data Valid but Above derate increasing in ant level in the menu 7
Normal Operational Range - severity from time of engine, top up
Least Severe Level. Intake alert. as needed.
manifold air temperature sig- Check that the
nal indicates intake manifold charge-air cooler
air temperature above engine is clean, clean
protection warning limit. as needed.
Check that fan
belts are intact.
Check the sen-
sor.
108 / 2 P108 / 2 Barometric pressure: Data er- Engine power derate. Check cabling - -
ratic, intermittent, or incorrect. between control
The ambient air pressure sen- unit and compo-
sor reads an erratic value nent.
upon activation. Check the sen-
sor.
108 / 3 P108 / 3 Barometric Pressure Sensor Engine power derate. Check cabling D794 -
Circuit - Voltage Above Nor- between control
mal, or Shorted to High unit and compo-
Source. High signal voltage nent.
detected at barometric pres- Check the sen-
sure circuit. sor.
108 / 4 P108 / 4 Barometric Pressure Sensor Engine power derate. Check cabling D794 -
Circuit - Voltage Below Nor- between control
mal, or Shorted to Low unit and compo-
detected at barometric pres- Check the sen-
sure circuit. sor.


tions and tic menu
compo-
nents
Code J1587
110 / 0 P110 / 0 Engine Coolant Temperature Progressive power Check coolant - ENGINE,
- Data Valid but Above Normal derate increasing in level. menu 7
Operational Range - Most Se- severity from time af- Check that radi-
vere Level. Engine coolant ter alert. If the Engine ator is clean.
temperature signal indicates Protection Shutdown
engine coolant temperature Check if there’s
feature is enabled,
above engine protection criti- engine will shut down air in coolant
cal limit. system.
red STOP lamp starts Check the cap
flashing. on the expan-
sion tank.
Check the sen-
sor.
Check thermo-
stat.
110 / 2 P110 / 2 Engine Coolant Temperature The ECU 794 will es- Check cabling D794 ENGINE,
- Data Erratic, Intermittent, or timate engine coolant between control menu 7
Incorrect. The engine coolant temperature. unit and compo-
temperature reading is not nent.
changed with engine operat- Check the sen-
ing conditions. sor.
110 / 3 P110 / 3 Engine Coolant Temperature Possible white Check cabling D794 ENGINE,
1 Sensor Circuit - Voltage smoke. Fan will stay between control menu 7
Above Normal or Shorted to ON if controlled by unit and compo-
High Source. High signal volt- ECU 794. No engine nent.
age or open circuit detected at protection for engine Check the sen-
engine coolant temperature coolant temperature. sor.
circuit.
110 / 4 P110 / 4 Engine Coolant Temperature Possible white Check cabling D794 ENGINE,
1 Sensor Circuit - Voltage Be- smoke. Fan will stay between control menu 7
low Normal or Shorted to Low ON if controlled by unit and compo-
Source. Low signal voltage ECU 794. No engine nent.
detected at engine coolant protection for engine Check the sen-
temperature circuit. coolant temperature. sor.


tions and tic menu
compo-
nents
Code J1587
110 / 15 P110 / 0 Engine Coolant Temperature Progressive power Check coolant D794 ENGINE,
High - Data Valid but Above derate increasing in level. menu 7
Normal Operational Range - severity from time of Check that radi-
Least Severe Level. Engine alert. ator is clean.
coolant temperature signal in-
Check if there’s
dicates coolant temperature is
air in coolant
above the engine coolant tem-
system.
perature engine protection
warning limit. Check the cap
on the expan-
sion tank.
Check the sen-
sor.
Check thermo-
stat.
110 / 16 P110 / 0 Engine Coolant Temperature Progressive power Check coolant D794 ENGINE,
- Data Valid but Above Normal derate increasing in level. menu 7
Operational Range - Moder- severity from time of Check that radi-
ately Severe Level. Engine alert. ator is clean.
coolant temperature signal in-
Check if there’s
dicates engine coolant tem-
air in coolant
perature is above engine
system.
protection warning limit.
Check the cap
on the expan-
sion tank.
Check the sen-
sor.
Check thermo-
stat.
111 / 1 P111 / 1 Coolant Level - Data Valid but Progressive power Check the cool- - -
Below Normal Operational derate increasing in ant level, top up
Range - Most Severe Level. severity from time af- if needed.
Low engine coolant level de- ter alert. If the engine Check the sen-
tected. protection shutdown sor.
feature is enabled,
engine will shut down
flashing.


tions and tic menu
compo-
nents
Code J1587
111 / 3 P111 / 3 Coolant Level Sensor Circuit - None on perform- Check cabling D794 -
Voltage Above Normal or ance. between control
Shorted to High Source. High unit and compo-
signal voltage detected at en- nent.
gine coolant level circuit. Check the sen-
sor.
111 / 4 P111 / 4 Coolant Level Sensor Circuit - None on perform- Check cabling D794 -
Voltage Below Normal or ance. between control
Shorted to Low Source. Low unit and compo-
signal voltage detected at the nent.
engine coolant level circuit. Check the sen-
sor.
157 / 0 P94 / 0 Injector Metering Rail Number None or possible en- - D794 -
1 Pressure - Data Valid But gine noise associated
Above Normal Operating with higher injection
Range - Most Severe Level. pressures (especial-
The ECU 794 has detected ly at idle or light load).
that fuel pressure in the rail Engine power is re-
fuel is higher than the com- duced.
manded pressure.
157 / 2 P157 / 2 Injector Metering Rail 1 Pres- The ECU 794 will es- - D794 -
sure - Data Erratic, Intermit- timate fuel pressure,
tent, or Incorrect. the ECU and power is re-
794 has detected that the fuel duced.
pressure signal is not chang-
ing.
157 / 3 P157 / 3 Injector Metering Rail Number Power and or speed - D794 -
1 Pressure Sensor Circuit - derate.
Voltage Above Normal or
Shorted to High Source. High
signal voltage detected at rail
fuel pressure sensor circuit.
157 / 4 P157 / 4 Injector Metering Rail Number Power and or speed - D794 -
1 Pressure Sensor Circuit - derate.
Voltage Below Normal or
Shorted to Low Source. Low
signal voltage detected at the
rail fuel pressure sensor cir-
cuit.


tions and tic menu
compo-
nents
Code J1587
157 / 16 P157 / 0 Injector Metering Rail 1 Pres- None or possible en- - D794 -
sure - Data Valid but Above gine noise associated
Normal Operational Range - with higher injection
Moderately Severe Level. The pressures (especial-
ECU 794 has detected that ly at idle or light load).
fuel pressure is higher than Engine power is re-
commanded pressure. duced.
157 / 18 P157 / 1 Fuel Pump Delivery Pressure Possibly hard to start, - D794 -
Low - Data Valid but Below low power, or engine
Normal Operational Range - smoke. Engine can
Moderately Severe Level. The possibly not start.
ECU 794 has detected that
fuel pressure is lower than
commanded pressure.
167 / 1 P167 / 1 Electrical Charging System Warning lamp illumi- Check batteries D794 -
Voltage Low - Data Valid but nated until very low and alternator.
Below Normal Operational battery voltage condi-
Range - Most Severe Level. tion is corrected.
Very low battery voltage de-
tected by the battery voltage
monitor feature.
167 / 16 P167 / 0 Electrical Charging System Amber warning lamp Check fuses. D794 -
Voltage High - Data Valid but illuminated until high Check batteries
Above Normal Operational battery voltage condi- and alternator.
Range - Moderately Severe tion is corrected.
Level. High battery voltage
detected by the battery volt-
age monitor feature.
167 / 18 P167 / 1 Electrical Charging System Amber lamp will light Check batteries D794 -
Voltage Low - Data Valid but until low battery volt- and alternator.
Below Normal Operational age condition is cor-
Range - Moderately Severe rected.
Level. Low battery voltage de-
tected by the battery voltage
monitor feature.
168 / 16 P168 / 0 Battery 1 Voltage - Data Valid Possible electrical Check fuses. D794 -
but Above Normal Operation- damage to all electri- Check batteries
al Range - Moderately Severe cal components. and alternator.
Level. ECU 794 supply volt-
age is above the maximum
system voltage level.


tions and tic menu
compo-
nents
Code J1587
168 / 18 S168 / 1 Battery 1 Voltage - Data Valid Engine may stop run- Check fuses. D794 -
but Below Normal Operational ning or be difficult to Check batteries
Range - Moderately Severe start. and alternator.
Level. ECU 794 supply volt-
age is below the minimum
system voltage level.
171 / 3 P171 / 3 Ambient temperature sensor, - D794 -

circuit fault- Abnormally high
voltage or short-circuit to high-
er voltage.
171 / 4 P171 / 4 Ambient temperature sensor, - D794 -

circuit fault - Abnormally low
voltage or short-circuit to low-
er voltage.
190 / 0 P190 / 0 Engine Crankshaft Speed/Po- Fuel injection disa- Ease off throttle - -
sition - Data Valid but Above bled until engine or select higher
Normal Operational Range - speed fails below the gear.
Most Severe Level. Engine overspeed limit.
speed signal indicates engine
speed above engine protec-
tion limit.
190 / 2 P190 / 2 Engine Crankshaft Speed/Po- Engine can exhibit Check cabling D794 -
sition - Data Erratic, Intermit- misfire as control between control
tent, or Incorrect. Crankshaft switches from the pri- unit and compo-
engine speed sensor intermit- mary to the backup nent.
tent synchronization. speed sensor. En- Check the sen-
gine power is re- sor.
duced while the
engine operates on
the backup speed
sensor.
190 / 2 P190 / 2 Engine Crankshaft Speed/Po- Engine can run Check cabling D794 -
sition - Data Erratic, Intermit- rough. Possibly poor between control
tent, or Incorrect. Loss of starting capability. unit and compo-
signal from crankshaft sensor. Engine runs using nent.
backup speed sen- Check the sen-
sor. Engine power is sor.
reduced.
251 / 2 P251 / 2 Real-Time Clock Power Inter- None on perform- - - -

rupt - Data Erratic, Intermittent ance. Data in the
or Incorrect. Real-time clock ECU 794 will not
lost power. have accurate time
and date information.


tions and tic menu
compo-
nents
Code J1587
441 / 3 P441 / 3 Auxiliary Temperature Sensor None on perform- Check cabling D794 -
Input 1 - Voltage Above Nor- ance. between control
mal, or Shorted to High unit and compo-
Source. High signal voltage or nent.
open circuit detected at the Check the sen-
OEM auxiliary temperature sor.
circuit.
441 / 4 P441 / 4 Auxiliary Temperature Sensor None on perform- Check cabling D794 -
Input 1 Circuit - Voltage Below ance. between control
Normal, or Shorted to Low unit and compo-
detected at OEM auxiliary Check the sen-
temperature circuit. sor.
558 / 2 S230 / 2 Accelerator Pedal or Lever Engine will only idle. Check cabling D794 -
Idle Validation Circuit - Data between control
Erratic, Intermittent or Incor- unit and compo-
rect. Voltage detected simul- nent.
taneously on both idle Check compo-
validation and off-idle valida- nent.
tion switches.
Idle Validation Circuit - Volt- between control
age Below Normal or Shorted unit and compo-
to Low Source. No voltage de- nent.
tected simultaneously on both Check compo-
the idle validation off-idle and nent.
on-idle circuits.
Idle Validation Circuit - Out of between control
Calibration. Voltage at idle unit and compo-
validation on-idle and off-idle nent.
circuit does not match accel- Check compo-
erator pedal position. nent.
611 / 2 P089 / 2 Auxiliary Intermediate (PTO) Intermediate speed - D794 -

Speed Switch Validation - control switch may
Data Erratic, Intermittent, or not operate correctly.
Incorrect. The position of the
intermediate speed control
switch 1 does not match the
position of the intermediate
speed control validation
switch.


tions and tic menu
compo-
nents
Code J1587
611 / 3 S232 / 3 Sensor Supply Voltage 4 Cir- Engine will only idle. - D794 -
cuit - Voltage Above Normal
or Shorted to High Source.
High voltage detected at +5
volt sensor supply circuit to
the accelerator pedal position
sensor.
611 / 4 S232 / 4 Sensor Supply 3 Circuit - Volt- Possible hard starting - D794 -
age Below Normal, or Shorted and rough running.
to Low Source. Low voltage
detected on the +5 volt sensor
supply circuit to the engine
speed sensor.
611 / 4 S232 / 4 Sensor Supply Voltage 4 Cir- Engine will only die. - D794 -
cuit - Voltage Below Normal or
voltage detected at +5 VDC
sensor supply circuit to the ac-
celerator pedal position sen-
sor..
611 / 15 S151 / 0 Turbocharger compressor Fuel is limited in an - D794 -

outlet temperature - data attempt to decrease
above normal. High turbo- the calculated turbo-
charger compressor outlet charger compressor
temperature has been calcu- outlet temperature.
lated by the ECU 794.
612 / 2 P190 / 2 Engine Magnetic Crankshaft Fueling to the injec- - D794 -

Speed/Position lost both of tors is disabled, and
two signals - Data Erratic, In- the engine can not be
termittent, or Incorrect. The started.
ECU 794 has detected that
the primary engine speed
sensor and the backup engine
speed sensor signals are re-
versed.
627 / 2 S251 / 2 Power Lost without Ignition Possible no noticea- Check fuses. D794 -
Off - Data Erratic, Intermittent ble performance ef- Check batteries
or Incorrect. Supply voltage to fects or engine dying and alternator.
the ECU 794 fell below 6.2 or hard starting. Fault
volts momentarily, or the ECU information, trip infor-
794 was not allowed to power mation, and mainte-
down correctly (retain battery nance monitor data
voltage for 30 seconds after can be inaccurate.
key OFF).


tions and tic menu
compo-
nents
Code J1587
627 / 2 S251 / 2 Power Supply Lost With Igni- Possible no noticea- Check fuses. D794 -
tion On - Data Erratic, Inter- ble performance ef- Check batteries
mittent or Incorrect. Supply fects or engine dying and alternator.
voltage to the ECU 794 fell or hard starting. Fault
below 6.2 VDC momentarily, information, trip infor-
or the ECU 794 was not al- mation, and mainte-
lowed to power down correctly nance monitor data
(retain battery voltage for 30 can be inaccurate.
seconds after key OFF).
627 / 2 S254 / 12 Injector Power Supply - Bad Possible smoke, low Check fuses. D794 -
Intelligent Device or Compo- power, engine mis- Check batteries
nent. The ECU 794 measured fire, and/or engine and alternator.
injector boost voltage is low. will not start.
629 / 12 S254 / 12 Engine Control Module - criti- Engine may not start. Check the con- D794 -
cal internal failure. Error inter- trol unit.
nal to the ECU 794 related to
memory hardware failures or
internal ECU 794 voltage sup-
ply circuits.
629 / 12 S254 / 12 Engine Control Module Warn- No performance ef- Check the con- D794 -
ing Internal Hardware Failure fects or possible se- trol unit.
- Bad Intelligent Device or vere power derate.
Component.
630 / 2 S253 / 2 Engine Control Module Data Possible no noticea- Re-program the D794 -
Lost - Data Erratic, Intermit- ble performance ef- software in Con-
tent or Incorrect. Severe loss fects or engine dying trol unit engine
of data from the ECU 794. or hard starting. Fault (D794).
information, trip infor-
mation, and mainte-
nance monitor data
can be inaccurate.
630 / 31 S240 / 11 Engine Control Module Cali- Possible no noticea- - D794 -

bration Program Memory ble performance ef-
(RAM) Corruption - Condition fects or engine dying
Exists. Severe loss of data or hard starting. Fault
from the ECU 794. information, trip infor-
mation, and mainte-
nance monitor data
can be inaccurate.


tions and tic menu
compo-
nents
Code J1587
633 / 31 S018 / 11 Fueling Actuator Number 1 Possible low power. - D794 -
Circuit Error Conditions Ex-
ists. Fuel pump actuator cir-
cuit resistance too high or too
low.
639 / 9 S231 / 9 SAE J1939 Multiplexing PGN One or more multi- Use diagnostic - CAN/POW-
Timeout Error - Abnormal Up- plexed devices will menu to find in- ER, menu 2
date Rate. The Cummins not operate properly. correct segment.
ECU 794 did not receive a One or more symp-
multiplexed message from an toms will occur
OEM VECU within the time
limit or did not receive it at all.
639 / 13 S231 / 13 SAE J1939 Multiplexing Con- At least one multi- Use diagnostic - CAN/POW-
figuration Error - Out of Cali- plexed devices will menu to find in- ER, menu 2
bration. The ECU 794 not operate properly. correct segment.
expected information from a
multiplexed device but only
received a portion of the nec-
essary information.
641 / 3 S027 / 3 VGT actuator driver circuit - Possible low power. - D794 -
voltage above normal or Power removed from
shorted to high source. the turbocharger ac-
tuator motor.
641 / 4 S027 / 4 VGT actuator driver circuit - Possible low power. - D794 -
voltage below normal, or Power removed from
shorted to low source. the turbocharger ac-
tuator motor.
644 / 2 S030 / 2 External Speed Command In- Primary or secondary Check cabling - -
put (Multiple Unit Synchroni- engines may be shut between control
zation) - Data Erratic, down unit and compo-
Intermittent, or Incorrect. The nent.
throttle input signal to the pri- Check compo-
mary or secondary engine for nent.
multiple unit synchronization
is less than 3 percent or more
than 97 percent.
647 / 3 S033 / 3 Fan Control Circuit - Voltage The fan may stay on Check cabling D794 -
Above Normal or Shorted to continuously or not between control
High Source. Open circuit or run at all. unit and compo-
high voltage detected at the nent.
fan control circuit. Check compo-
nent.


tions and tic menu
compo-
nents
Code J1587
647 / 4 S033 / 4 Fan Control Circuit - Voltage The fan may stay on Check cabling D794 -
Below Normal or Shorted to continuously or not between control
Low Source. Low signal volt- run at all. unit and compo-
age detected at the fan control nent.
circuit when commanded on. Check compo-
nent.
651 / 5 S001 / 5 Injector Solenoid Driver Cylin- Engine can misfire or Check cabling D794 -
der 1 Circuit - Current Below possibly run rough. between control
Normal, or Open Circuit. High unit and compo-
resistance or no current de- nent.
tected at Number 1 injector Check the injec-
DRIVER or RETURN pin. tor.
651 / 7 S001 / 7 Injector Solenoid Driver Cylin- Engine will shut Check cabling D794 -
der 1 - Mechanical System down. between control
Not Responding Properly or unit and compo-
Out of Adjustment. Unintend- nent.
ed fueling detected in cylinder Check the injec-
number 1. tor.
driver or return pin. tor.
number 2. tor.
tected at Number 3 injector or Check the injec-
return pin. tor.


tions and tic menu
compo-
nents
Code J1587
number 3. tor.
Normal or Open Circuit. High unit and compo-
number 4. tor.
DRIVER or RETURN pin. tor.
Number 5. tor.


tions and tic menu
compo-
nents
Code J1587
Number 6. tor.
677 / 3 S39 / 3 Starter Relay Circuit - Voltage Either the engine will Check cabling D794 ENGINE,
Above Normal or Shorted to not start or the engine between control menu 5
High Source. Open circuit or will not have starter unit and compo-
high voltage detected at start- lockout protection. nent.
er lockout circuit. Check the relay.
677 / 4 S39 / 4 Starter Relay Circuit - Voltage The engine will not Check cabling D794 ENGINE,
Below Normal or Shorted to have starter lockout between control menu 5
Low Source. Low voltage de- protection. unit and compo-
tected at starter lockout cir- nent.
cuit. Check the relay.
697 / 3 S057 / 3 Auxiliary PWM Driver #1 - Can not control trans- - D794 -
Voltage Above Normal or mission.
Shorted to High Source. High
analog torque circuit.
697 / 4 S057 / 4 Auxiliary PWM Driver #1 - Can not control trans- - D794 -
Voltage Below Normal or mission.
analog torque circuit.
703 / 11 S051 /11 Auxiliary Equipment Sensor Possible engine pow- Check cabling D794 -
Input #3 (OEM Switch) - Root er derate. between control
Cause Not Known. unit and compo-
nent.
Check the com-
ponent.
723 / 2 S064 / 2 Backup Engine Speed/Posi- Possible low power. Check cabling D794 -
tion Sensor Number 2 - Data between control
Erratic, Intermittent, or Incor- unit and compo-
rect. Camshaft engine speed nent.
sensor intermittent synchroni- Check the sen-
zation. sor.


tions and tic menu
compo-
nents
Code J1587
723 / 2 S064 / 2 Engine Speed Sensor (Cam- Possible poor start- Check cabling D794 -
shaft) Error - Data Erratic, In- ing. Engine power between control
termittent, or Incorrect. The derate. unit and compo-
ECU 794 has detected an er- nent.
ror in the camshaft position Check the sen-
sensor signal. sor.
723 / 7 S064 / 7 Engine Speed Sensor/Posi- Engine will run derat- Check cabling D794 -
tion Camshaft and Crankshaft ed. Excessive between control
Misalignment - Mechanical smoke, hard start, unit and compo-
System Not Responding and rough idle possi- nent.
Properly or Out of Adjustment. ble. Check the sen-
Mechanical misalignment be- sor.
tween the crankshaft and
camshaft engine speed sen-
sors.
729 / 3 S070 / 3 Intake Air Heater #1 Circuit - The intake air heaters Check cabling D794 -
Voltage Above Normal or may be ON or OFF all between control
Shorted to High Source. High the time. unit and compo-
voltage detected at the intake nent.
air heater signal circuit. Check compo-
nent.
729 / 4 S070 / 4 Intake Air Heater #1 Circuit - The intake air heaters Check cabling D794 -
Voltage Below Normal or may be ON or OFF all between control
Shorted to Low Source. Low the time. unit and compo-
voltage detected at the intake nent.
air heater signal circuit. Check compo-
nent.
974 / 3 P974 / 3 Remote Accelerator Pedal or Remote accelerator Check cabling D794 -
Lever Position Sensor 1 Cir- will not operate. Re- between control
cuit - Voltage Above Normal, mote accelerator po- unit and compo-
or shorted to High Source. sition will be set to nent.
High voltage detected at re- zero percent. Check compo-
mote accelerator pedal posi- nent.
tion circuit.
974 / 4 P974 / 4 Remote Accelerator Pedal or Remote accelerator Check cabling D794 -
Lever Position Sensor 1 Cir- will not operate. Re- between control
cuit - Voltage Below Normal, mote accelerator po- unit and compo-
or Shorted to Low Source. sition will be set to nent.
Low voltage detected at re- zero percent. Check compo-
mote accelerator pedal posi- nent.
tion signal.


tions and tic menu
compo-
nents
Code J1587
974 / 19 P29 SAE J1939 Multiplexing Re- The engine will not Use diagnostic - CAN/POW-
mote Accelerator Pedal or Le- respond to the re- menu to find in- ER, menu 2
ver Data Error - Received mote throttle. Engine correct segment.
Network Data Error. The OEM may only idle. The
machine electronic control primary or cab accel-
unit (VECU) detected a fault erator may be able to
with the remote accelerator. be used.
Position Sensor Supply Volt- between control
age Circuit - Voltage Above unit and compo-
Normal or Shorted to High nent.
Source. High voltage detected Check compo-
at sensor supply circuit for the nent.
accelerator pedal or lever po-
sition sensor..
1043 / 4 S221 / 4 Accelerator Pedal or Lever Engine will only die. Check cabling D794 -
Position Sensor Supply Volt- between control
age Circuit - Voltage Below unit and compo-
Normal or Shorted to Low nent.
Source. Low voltage detected Check compo-
at sensor supply circuit to the nent.
accelerator pedal or lever po-
sition sensor.
1043 / 4 S221 / 4 Engine Speed/Position Sen- Possible hard starting Check cabling D794 -
sor (Crankshaft) Supply Volt- and rough running. between control
age Circuit - Voltage Below unit and compo-
Normal or Shorted to Low nent.
Source. Low voltage detected Check compo-
on the ECU 794 voltage sup- nent.
ply line to engine speed sen-
sor.
1072 / 3 S028 / 3 Engine Brake Actuator Circuit Engine brake on cyl- Check cabling D794 -
#1 - Voltage Above Normal or inders 1, 2, and 3 can between control
Shorted to High Source. Open not be activated or unit and compo-
circuit or high voltage detect- exhaust brake will not nent.
ed at the engine brake sole- operate. Check compo-
noid number 1 signal circuit. nent.
#1 - Voltage Below Normal or inders 1, 2, and 3 can between control
Shorted to Low Source. Low not be activated or unit and compo-
voltage detected at the engine exhaust brake will not nent.
brake solenoid number 1 sig- operate. Check compo-
nal circuit. nent.


tions and tic menu
compo-
nents
Code J1587
#2 - Voltage Above Normal or inders 4, 5, and 6 can between control
Shorted to High Source. Open not be activated. unit and compo-
circuit or high voltage detect- nent.
ed at the engine brake sole- Check compo-
noid number 2 signal circuit. nent.
#2 - Voltage Below Normal or inders 4, 5, and 6 can between control
Shorted to Low Source. Low not be activated. unit and compo-
voltage detected at the engine nent.
brake solenoid number 2 sig- Check compo-
nal circuit. nent.
1075 / 3 S126 / 3 Electric Lift Pump for Engine Engine can be diffi- - D794 -
Fuel Supply Circuit - Voltage cult to start.
Above Normal, or Shorted to
High Source. High voltage or
open detected at the fuel lift
pump signal circuit.
1075 / 4 S126 / 4 Electric Lift Pump for Engine Engine can be diffi- - D794 -
Fuel Supply Circuit - Voltage cult to start.
Below Normal, or Shorted to
Low Source. Low signal volt-
age detected at the fuel lift
pump circuit.
1079 / 3 S212 / 3 Sensor Supply Voltage Engine power derate. Check cabling D794 -
number 1 Circuit - Voltage between control
Above Normal or Shorted to unit and compo-
High Source. High voltage de- nent.
tected at sensor supply Check the sen-
number 1 circuit. sor.
Number 1 Circuit - Voltage between control
Below Normal or Shorted to unit and compo-
Low Source. Low voltage de- nent.
tected at sensor supply Check the sen-


tions and tic menu
compo-
nents
Code J1587
1080 / 3 S232 / 3 Sensor Supply 2 Circuit - Volt- Engine power derate. Check cabling D794 -
age Above Normal or Shorted between control
to High Source. High voltage unit and compo-
detected at sensor supply nent.
number 2 circuit. Check the sen-
sor.
Number 2 Circuit - Voltage between control
Below Normal, or Shorted to unit and compo-
Low Source. Low voltage de- nent.
tected at the sensor supply Check the sen-
1137 / 2 S114 / 2 Multiple Unit Synchronization Multi-Unit synchroni- - D794 -

Switch - Data Erratic, Intermit- zation feature is disa-
tent, or Incorrect. Multi-Unit bled.
synchronous ON/OFF switch
and Multi-Unit synchronous
complimentary ON/OFF
switch have different values in
the ECU 794.
1172 / 3 /3 Turbocharger Number 1 Com- Engine power derate. - D794 -

pressor Inlet Temperature
Sensor Circuit - Voltage
Above Normal or Shorted to
High Source. High signal volt-
age detected at the turbo-
charger compressor inlet air
temperature circuit.
1172 / 4 /4 Turbocharger Number 1 Com- Engine power derate. - D794 -

pressor Inlet Temperature
Sensor Circuit - Voltage Be-
low Normal or Shorted to Low
Source. Low signal voltage
detected at the turbocharger
compressor inlet air tempera-
ture sensor circuit.
1347 / 3 S126 / 3 High Fuel Pressure Solenoid Engine will run poorly - D794 -
Valve Circuit - Voltage Above but will be severely
Normal or Shorted to High derated. Rail pres-
Source. Electronic fuel control sure will be higher
actuator shorted high. than commanded.


tions and tic menu
compo-
nents
Code J1587
1347 / 4 S126 / 4 High Fuel Pressure Solenoid Engine will run poorly - D794 -
Valve Circuit - Voltage Below at idle. Engine will
Normal or Shorted to Low have low power. Fuel
Source. Electronic fuel control pressure will be high-
actuator shorted low. er than commanded.
1347 / 7 S126 / 7 Fuel Pump Pressurizing As- Engine will not run or - D794 -
sembly 1 - Mechanical Sys- possible low power
tem Not Responding Properly
or Out of Adjustment. A pump-
ing imbalance between the
front and rear pumping plung-
ers has been detected.
1347 / 7 S126 / 7 Fuel Pumping Element Engine will not run or - D794 -
Number 1 (Front) - Mechani- possible low power
cal System Not Responding
Properly or Out of Adjustment.
1378 / 31 S153 / 11 Change Lubricating Oil and None on perform- - D794 -

Filter - Condition Exists. ance; maintenance
Change engine oil and filter. reminder only.
1388 / 3 P223 / 3 Auxiliary Pressure Sensor In- None on perform- - D794 -

put 1 Circuit - Voltage Above ance.
Normal, or Shorted to High
Source. High signal voltage
detected at the OEM pressure
circuit.
1388 / 4 P223 / 4 Auxiliary Pressure Sensor In- None on perform- - D794 -

put 1 Circuit - Voltage Below ance.
Normal, or Shorted to Low
Source. Low signal voltage or
open circuit detected at the
OEM pressure circuit.
2789 / 15 /0 Exhaust gas temperature - Derate in power out- - D794 -

data above normal. High ex- put of the engine in
haust temperature has been attempt to decrease
calculated by the electronic the calculated ex-
control system. haust gas tempera-
ture value.

Error codes (Cummins QSM 11

page
–
engine)
tions and tic menu
compo-
nents
Code Flash J1587
84/2 241 PID084/ Electrical error, Engine rpm is lim- Check cabling between - -
2 speed sensor, ited to maximum control unit and compo-
invalid data. rpm without gear. nent.
Check the sensor.
84/10 242 PID084/ Electrical error, Engine rpm is lim- Check cabling between - -
10 speed sensor, signal ited to maximum control unit and compo-
manipulation detect- rpm without gear. nent.
ed. Check the sensor.
91/3 131 PID091/ Electrical error, ac- Engine does not Check cabling between - -
3 celerator pedal, ca- respond to throt- control unit and compo-
ble short circuited to tle. nent.
supply voltage. Check the component.
4 celerator pedal, ca- respond to throt- control unit and compo-
ble short circuited to tle. nent.
ground. Check the component.
8 celerator pedal, low respond to throt- control unit and compo-
frequency. tle. nent.
Check the component.
8 celerator pedal, high respond to throt- control unit and compo-
frequency. tle. nent.
91/19 287 SID091/ Communication er- Engine will only Use diagnostic menu to - CAN/POW-
2 ror with cab control idle. find incorrect segment. ER, menu 4
unit (D790-1), elec-
trical error, accelera-
tor pedal.
97/3 428 PID097/ Electrical error, wa- No limitation. Check cabling between D794/Sen- -
3 ter-in-fuel sensor, control unit and compo- sor:09
cable short circuited nent.
to supply voltage. Check the component.


tions and tic menu
compo-
nents
Code Flash J1587
97/4 429 PID097/ Electrical error, wa- No limitation. Check cabling between D794/Sen- -
4 ter-in-fuel sensor, control unit and compo- sor:09
to ground. Check the component.
97/15 418 PID097/ Water in fuel. Risk of white ex- Drain water from the fuel - -
15 haust smoke and filter.
reduced engine
output.
100/1 415 PID100/ Low engine oil pres- Engine output is Check the engine oil lev- - ENGINE,
1 sure. reduced gradual- el; fill as necessary. menu 6
ly. The engine is
switched off after
30 seconds.
100/2 435 PID100/ Oil pressure sensor, No warning of low Check the sensor. D794/Sen- ENGINE,
2 data error. engine oil pressor:44 menu 6
sure.
100/3 135 PID100/ Sensor oil pressure, No warning of low Check cabling between D794/Sen- ENGINE,
3 cable short circuited engine oil pres- control unit and compo- sor:44 menu 6
to supply voltage. sure. nent.
Check the sensor.
100/4 141 PID100/ Oil pressure sensor, No warning of low Check cabling between D794/ ENGINE,
4 open circuit or short engine oil pres- control unit and compo- Black:14 menu 6
circuit to ground. sure. nent.
Check the sensor.
100/ 143 PID100/ Low engine oil pres- No limitation. Check oil level in the en- - ENGINE,
18 1 sure. gine, top up as needed. menu 6
Check the sensor.
102/2 433 PID102/ Boost pressure sen- Reduced engine Check cabling between D794/Sen- ENGINE,
2 sor indicates high power. control unit and compo- sor:39 menu 7
boost pressure but nent.
other engine data in- Check the sensor.
dicates that pressure
should be normal.
102/3 122 PID102/ Sensor boost pres- Reduced engine Check cabling between D794/Sen- ENGINE,
3 sure, cable short- power. control unit and compo- sor:39 menu 7
circuited to voltage. nent.
Check the sensor.


tions and tic menu
compo-
nents
Code Flash J1587
102/4 123 PID102/ Boost pressure sen- Reduced engine Check cabling between D794/ ENGINE,
4 sor, cable short power. control unit and compo- Black:3 menu 7
circuited to ground nent.
or open circuit. Check the boost pres-
sure sensor.
103/ 595 PID103/ Over-rev protection, Reduced engine Check the component. - -
16 0 turbo. power.
105/0 155 PID105/ Intake air too hot. Engine output is Check the coolant level - ENGINE,
0 reduced gradual- in the engine, top up as menu 7
ly. The engine is needed.
switched off after Check that the charge-
30 seconds. air cooler is clean, clean
as needed.
Check that the fan belts
are intact. Check the in-
take air temperature
sensor.
105/3 153 PID105/ Charge air tempera- Risk of white ex- Check cabling between D794/Sen- ENGINE,
3 ture sensor, cable haust smoke. No control unit and compo- sor:38 menu 7
short circuited to warning of high nent.
supply voltage or coolant tempera- Check that the charge air
open circuit. ture. temperature sensor is
correctly installed and
connected.
Check the charge air
temperature sensor.
105/4 154 PID105/ Charge air tempera- Risk of white ex- Check cabling between D794/Sen- ENGINE,
4 ture sensor, cable haust smoke. No control unit and compo- sor:38 menu 7
short circuited to warning of high nent.
ground or open cir- coolant tempera- Check that the sensor is
cuit. ture. correctly installed and
connected.
Check the sensor.
108/2 295 PID108/ Electrical error, air Reduced engine Check the sensor. - -
2 pressure sensor, power.
data error.
108/3 221 PID108/ Electrical error, air Reduced engine Check cabling between D794/Sen- -
3 pressure sensor, ca- power. control unit and compo- sor:06
ble short circuited to nent.
supply voltage. Check the sensor.


tions and tic menu
compo-
nents
Code Flash J1587
108/4 222 PID108/ Electrical error, air Reduced engine Check cabling between D794/Sen- -
4 pressure sensor, ca- power. control unit and compo- sor:06
ble short circuited to nent.
ground. Check the sensor.
110/0 151 PID110/ High coolant temper- Engine output is Check coolant level. - ENGINE,
0 ature. reduced gradual- Check that radiator is menu 7
ly. The engine is clean.
switched off after
Check if there’s air in
30 seconds.
coolant system.
Check the cap on the ex-
pansion tank.
Check the sensor.
Check thermostat.
110/3 144 PID110/ Coolant temperature No indication of Check cabling between D794/Sen- ENGINE,
3 sensor, cable short engine tempera- control unit and compo- sor:02 menu 7
circuited to supply ture. nent.
voltage or open cir-
cuit.
110/4 145 PID110/ Coolant temperature No indication of Check cabling between D794/Sen- ENGINE,
4 sensor, cable short engine tempera- control unit and compo- sor:02 menu 7
circuited to ground. ture. nent.
Check that the sensor is
connected correctly.
Check the sensor.
111/1 235 PID111/ Low coolant level. Engine output is Check the coolant level, - -
1 reduced gradual- top up if needed.
ly. The engine is Check the sensor.
switched off after
30 seconds.
111/2 422 PID111/ Electrical error, cool- No warning of low Check cabling between D794/Sen- -
2 ant level sensor, coolant level. control unit and compo- sor:09
data error. nent.
Check the sensor.
166/2 951 PID116/ Output imbalance Uneven idling. Check the fuel grade. - -
2 between cylinders. The error code could be
generated if the fuel sys-
tem is opened, allowing
air to enter the system.
Troubleshoot the engine.


tions and tic menu
compo-
nents
Code Flash J1587
167/1 598 PID167/ Low battery voltage. Warning active Check batteries and al- D794/ -
1 until voltage is cor- ternator. OEM:7, 8,
rect. 17, 18, 28
167/ 596 PID167/ Low battery voltage. Warning active Check fuses. Check bat- D794/ -
16 0 until voltage is cor- teries and alternator. OEM:7, 8,
rect. 17, 18, 28
167/ 597 PID167/ High battery voltage. Warning active Check batteries and al- D794/ -
18 1 until voltage is cor- ternator. OEM:7, 8,
rect. The engine 17, 18, 28
runs at increased
idle to increase
voltage.
168/ 442 PID168/ High voltage supply No limitation. Check fuses. Check bat- D794/ -
16 0 to control unit. teries and alternator. OEM:7, 8,
17, 18, 28
168/ 441 PID168/ Low voltage supply Uneven idling. Check fuses. Check bat- D794/ -
18 1 to control unit. teries and alternator. OEM:7, 8,
17, 18, 28
175/0 214 PID175/ High engine oil tem- Engine output is Check the engine cool- - ENGINE,
0 perature. reduced gradual- ant and oil level. Top up menu 7
ly. The engine is as necessary.
switched off after Check that the oil cooler
30 seconds. is clean; clean as need-
ed.
Check that the fan belts
are intact.
Check the sensor.
175/3 212 PID175/ Oil temperature sen- No indication of Check cabling between D794/Sen- ENGINE,
3 sor, cable short engine oil temper- control unit and compo- sor:42 menu 7
circuited to supply ature. nent.
voltage or open cir- Check that the sensor is
cuit. connected correctly.
175/4 213 PID175/ Oil temperature sen- No indication of Check cabling between D794/Sen- ENGINE,
4 sor, cable short engine oil temper- control unit and compo- sor:42 menu 7
circuited to ground. ature. nent.
Check the sensor.


tions and tic menu
compo-
nents
Code Flash J1587
188/4 466 SID032/ Electrical error, Reduced engine Check cabling between D794/Actu-
4 wastegaste sole- power. control unit and compo- ator: 24
noid valve 1 short nent.
circuited to ground. Check the solenoid
valve.
190/0 234 PID190/ Engine rpm too high. Fuel supply Ease off throttle or select - -
0 choked until en- higher gear.
gine rpm is below
permitted value.
190/2 115 PID190/ Electrical error, rpm/ Engine stops and Check cabling between D794/Sen- -
2 ignition mode sen- cannot be restart- control unit and compo- sor:47, 50
sor; no signal from ed. nent.
any sensors. Check the sensor.
190/ 121 PID190/ Electrical error, rpm/ No limitation. Check cabling between D794/Sen- -
10 10 ignition mode sen- control unit and compo- sor:47, 50
sor, one of two sig- nent.
nals missing. Check the sensor.
191/ 349 PID191/ Speed limitation acti- Speed is reduced. Reduce throttle applica- - -
16 0 vated. tion.
191/ 489 PID191/ Speed warning for Engine will only Increase throttle applica- - -
18 1 low speed. idle. tion.
251/2 319 PID251/ Internal error, engine - - - -

2 control unit.
441/3 293 PID441/ Auxiliary tempera- No warning of high Check cabling between D794/Sen-
3 ture sensor short temperature, en- control unit and compo- sor:12
circuited to ground. gine control unit nent.
(D794). Check the sensor.
441/4 294 PID441/ Auxiliary tempera- No warning of high Check cabling between D794/Sen-
4 ture sensor short temperature, en- control unit and compo- sor:12
circuited to supply gine control unit nent.
voltage. (D794). Check the sensor.
558/2 431 SID230/ Electrical error, ac- No limitation. Check cable between D794/ -
2 celerator pedal sen- control unit and compo- OEM:03, 13
sor, idling contact, nent.
data error. Check component.


tions and tic menu
compo-
nents
Code Flash J1587
558/4 551 SID230/ Electrical error, ac- Engine does not Check cable between D794/ -
4 celerator pedal sen- respond to throt- control unit and compo- OEM:03, 13
sor, idling contact tle. nent.
cable short circuited Check component.
to ground.
558/ 432 SID230/ Electrical error, ac- Engine will only Check cable between D794/ -
13 13 celerator pedal sen- idle. control unit and compo- OEM:13
sor, idling contact, nent.
calibration error. Check component.
608/2 412 SID250/ Communication er- No limitation. Check the control unit. D794/
2 ror with Control unit OEM:26,
engine (D794). 27, 36, 37,
46
608/9 414 SID250/ Communication er- No limitation. Check the control unit. D794/
9 ror with Control unit OEM:26,
engine (D794). 27, 36, 37,
46
620/3 227 SID232/ Electrical error, ref- Reduced engine Check cabling between D794/Sen- -
1080/ 3 erence voltage to output. No warn- control unit and compo- sor:18, 25,
3 sensor short ing of low oil pres- nent. 45
circuited to supply sure or low Check the control unit.
voltage. coolant level.
620/4 187 SID232/ Electrical error, ref- Reduced engine Check cabling between D794/Sen- -
1081/ 4 erence voltage to output. No warn- control unit and compo- sor:18, 25,
4 sensor short ing of low oil pres- nent. 45
circuited to ground. sure or low Check the component.
coolant level.
626/ 381 SID237/ Electrical error to Preheating does Check cabling between D794/Actu- ENGINE,
11 11 control of preheating not work. Risk of control unit and compo- ator: 34 menu 5
relay. white smoke. nent.
627/2 434 SID251/ Voltage supply to Reduced engine Check the fuses. D794/ -
2 control unit disap- output. Engine dif- Check batteries and al- OEM:7, 8,
pears but ignition not ficult to start or ternator. 17, 18, 28
off. dies.
629/ 111 SID254/ Internal error, engine The engine will not Check the control unit. - -
12 12 control unit. start.
629/ 343 SID254/ Internal error, engine No limitation. Check the control unit. - -
12 12 control unit.


tions and tic menu
compo-
nents
Code Flash J1587
630/2 341 SID253/ Software error, en- Reduced engine Re-program the software - -
2 gine control unit output. Engine dif- in Control unit engine
(D794). ficult to start or (D794).
dies.
632/3 255 SID017/ Electrical error, fuel No limitation. Check cabling between D794/Actu- -
3 cut-off solenoid control unit and compo- ator: 33
valve, cable short nent.
circuited to supply Check the solenoid
voltage. valve.
632/4 254 SID017/ Electrical error, fuel Engine will shut Check cabling between D794/Actu- -
4 cut-off solenoid down. control unit and compo- ator: 33
valve, cable short nent.
valve.
639/2 426 SID231/ Communication er- Functions via Use diagnostic menu to - CAN/POW-
2 ror with Control unit CAN bus not find incorrect segment. ER, menu 2
engine (D794). working.
9 ror with Control unit CAN bus not find incorrect segment. ER, menu 2
engine (D794). working.
9 ror with engine con- CAN bus not find incorrect segment. ER, menu 2
trol unit (D794), working.
timeout error.
639/ 286 SID231/ Communication er- Functions via Use diagnostic menu to - CAN/POW-
13 13 ror with Engine con- CAN bus not find incorrect segment. ER, menu 2
trol unit (D794), working.
configuration error.
644/2 237 SID030/ Electrical error, ac- Engine will shut Check cabling between - -
2 celerator pedal, sig- down. control unit and compo-
nal not within valid nent.
interval. Check the component.
647/4 245 SID033/ Electrical error, fan Cooling fan runs Check cabling between D794/Actu- -
4 connection, cable constantly. control unit and compo- ator:10, Ac-
short circuited to nent. tuator: 9
ground. Check the component.
651/5 322 SID001/ Electrical error, cyl- Engine runs on 5 Check cabling between D794/Actu- -
5 inder 1 injector, open cylinders, sounds control unit and compo- ator:10, Ac-
circuit on cable. rough and has re- nent. tuator: 9
duced power. Check the injector.


tions and tic menu
compo-
nents
Code Flash J1587
7 inder 1 injector, ca- cylinders, sounds control unit and compo- ator:10, Ac-
ble short circuited to rough and has re- nent. tuator: 9
ground. duced power. Check the injector.
5 inder 2 injector, open cylinders, sounds control unit and compo- ator: 7, 8
circuit on cable. rough and has re- nent.
6 inder 2 injector, ca- cylinders, sounds control unit and compo- ator: 7, 8
ble short circuited to rough and has re- nent.
653/6 313 SID003/ Electrical error, cyl- Engine runs on 5 Check cable between D794/Actu- -
ground. duced power. Check component.
ground. duced power. Check component.


tions and tic menu
compo-
nents
Code Flash J1587
duced power. Check component.
702/3 527 SID040/ Electrical error, aux- No limitation. Check cabling between D794/Actu- -
3 iliary output 2, cable control unit and compo- ator: 14
PID154/ short circuited to nent.
3 supply voltage. Check the component.
703/3 529 SID051/ Electrical error, aux- No limitation. Check cabling between D794/Actu- -
3 iliary output 2, cable control unit and compo- ator: 45
short circuited to nent.
supply voltage. Check the component.
974/3 133 SID029/ Electrical error, aux- Engine does not Check cabling between D794/OEM: -
3 iliary accelerator respond to throt- control unit and compo- 21
pedal, cable short tle. nent.
circuited to supply Check the component.
voltage.
974/4 134 SID029/ Electrical error, aux- Engine does not Check cabling between D794/OEM: -
4 iliary accelerator respond to throt- control unit and compo- 21
pedal, cable short tle. nent.
circuited to ground. Check the component.
974/ 288 SID029/ Communication er- Engine does not Use diagnostic menu to - CAN/POW-
19 2 ror with cab control respond to throt- find incorrect segment. ER, menu 2
unit (D790-1), elec- tle.
trical error, accelera-
tor pedal.
1043/ 387 PID221/ Electrical error, ac- Engine will only Check cabling between D794/OEM: -
3 3 celerator pedal refer- idle. control unit and compo- 48
ence voltage, cable nent.
short circuited to Check the component.
supply voltage.
1043/ 443 PID221/ Electrical error, ac- Engine will only Check cabling between D794/OEM: -
4 4 celerator pedal refer- idle. control unit and compo- 48
ence voltage, cable nent.
short circuited to Check the component.
ground.


tions and tic menu
compo-
nents
Code Flash J1587
1072/ 388 SID070/ Electrical error, sole- Engine brake 1 Check cabling between D794/Actu- -
11 11 noid valve engine cannot be activat- control unit and compo- ator: 44
brake 2. ed. nent.
Check the solenoid
valve.
1073/ 392 SID029/ Electrical error, sole- Engine brake 2 Check cabling between D794/Actu- -
11 11 noid valve engine cannot be activat- control unit and compo- ator: 44
brake 2. ed. nent.
Check the solenoid
valve.
1079/ 386 SID232/ Electrical error, ref- Reduced engine Check cabling between D794/Sen- -
3 3 erence voltage to power. control unit and compo- sor: 17, 37
sensor short nent.
circuited to supply Check the sensor.
voltage.
1079/ 352 SID232/ Electrical error, ref- Reduced engine Check cabling between D794/Sen- -
4 4 erence voltage to power. control unit and compo- sor: 17, 37
sensor short nent.
circuited to ground. Check the sensor.
1188/ 465 SID032/ Electrical error, Reduced engine Check cabling between D794/Actu- -
3 3 wastegate solenoid power. control unit and compo- ator: 24
valve 1 short nent.
voltage. valve.
1189/ 491 SID088/ Electrical error, Reduced engine Check cabling between D794/Actu-
3 3 wastegate solenoid power. control unit and compo- ator: 23
valve 2 short nent.
voltage. valve.
1189/ 492 SID88/4 Electrical error, Reduced engine Check cabling between D794/Actu-
4 wastegaste sole- power. control unit and compo- ator: 23
noid valve 2 short nent.
valve.
1265/ 223 SID085/ Electrical error, oil- No limitation. Check cabling between - -
4 4 burn solenoid valve, control unit and compo-
to ground. Check the solenoid
valve.


tions and tic menu
compo-
nents
Code Flash J1587
1319/ 419 PID102/ Electrical error, Reduced engine Check cabling between D794/Sen- -
2 2 boost pressure sen- power. control unit and compo- sor: 9
sor. nent.
Check the sensor.
1380/ 219 PID017/ Low engine oil level. No limitation. Check the engine oil lev- - -
1 1 el; fill as necessary.
1383/ 611 SID151/ Engine shut off other No limitation. Switch of the engine with - -
31 11 than with start key, the start key.
causing load.
1384/ 299 SID029/ Engine shut off other No limitation. Switch of the engine with - -
31 14 than with start key, the start key.
causing load.
1387/ 297 PID223/ Electrical error, aux- No pressure Check cabling between D794/Sen- -
3 3 iliary pressure sen- guard (customer- control unit and compo- sor: 19
sor, cable short specific option). nent.
circuited to supply Check the sensor.
voltage.
1387/ 298 PID223/ Electrical error, aux- No pressure Check cabling between D794/Sen- -
4 4 iliary pressure sen- guard (customer- control unit and compo- sor: 19
sor, cable short specific option). nent.
circuited to ground. Check the sensor.
1484/ 211 SID216/ Error codes in other No limitation. Check error codes for - -
31 11 control units. other machine control
units, particularly the cab
control unit (D790-1) and
transmission control unit
(D793).

Error codes engine (engine

page
–
alternative Volvo TAD760VE)

tions and tic menu
compo-
nents
Code Flash J1587
94/1 3.8 PID94/1 Low fuel pressure No limitation. Change fuel filter. - -
(feed). Change fuel pre-filter.
Check if pressure can be
built up with the hand
pump.
94/3 3.6 PID94/3 Sensor fuel pres- No limitation. Check cabling between D794/B:16 -
sure, short-circuited control unit and compo-
to voltage. nent.
Check the sensor.
94/5 3.6 PID94/5 Sensor fuel pres- No limitation. Check cabling between D794/B:16 -
Not 00.50
sure, short-circuited control unit and compo-
to ground or open nent.
circuit. Check the sensor.
94/7 3.8 PID94/7 Sensor fuel pres- No limitation. Change fuel filter. D794/B:16 -
sure, short-circuited Change fuel pre-filter.
to voltage, ground,
Check if pressure can be
or open circuit.
built up with the hand
pump.
97/0 2.1 PID97/0 Water in fuel. No limitation. Drain water separator. - -

Clean metal filter in the
fuel feed’s hose connec-
tion on the engine.
Check fuel filter and fuel
pre-filter.
97/4 2.9 PID97/4 Sensor water in fuel No limitation. Check cabling between D794/B:8 -
short-circuited to control unit and compo-
ground or open cir- nent.
cuit. Check the sensor.
100/0 6.6 PID100/ Low engine oil pres- Engine will shut Check oil level. - ENGINE,
0 sure. down. Change oil filter. menu 6
Check the system pres-

sure valves and the safe-
ty valve in the lubrication
system.
Check the sensor.


tions and tic menu
compo-
nents
Code Flash J1587
100/3 3.1 PID100/ Sensor oil pressure, No limitation. Check cabling between D794/B:11 ENGINE,
3 short-circuited to control unit and compo- menu 6
voltage. nent.
Check the sensor.
100/5 3.1 PID100/ Sensor, oil pres- No limitation. Check cabling between D794/B:11 ENGINE,
5 sure, open circuit. control unit and compo- menu 6
nent.
Check the sensor.
105/0 6.2 PID105/ High charge-air Engine will shut Check that the charge-air - ENGINE,
0 temperature. down. cooler is clean. menu 7
Check the sensor.
105/4 3.2 PID105/ Sensor charge-air No limitation. Check cabling between D794/A:47 ENGINE,
4 temperature, cable control unit and compo- menu 7
short-circuited to nent.
105/5 3.3 PID105/ Sensor charge-air No limitation. Check cabling between D794/A:47 ENGINE,
5 temperature, cable control unit and compo- menu 7
open circuit. nent.
Check the sensor.
106/0 3.5 PID106/ Boost pressure too Reduced engine Check the turbocharger. - ENGINE,
0 high. power. Check the sensor. menu 6
Check fuel quality and in-

jectors.
106/3 3.4 PID106/ Sensor boost pres- Reduced engine Check cabling between D794/A:22 ENGINE,
3 sure, cable short- power. control unit and compo- menu 7
Check the sensor.
106/5 3.4 PID106/ Sensor boost pres- Reduced engine Check cabling between D794/A:22 ENGINE,
5 sure, cable open power. control unit and compo- menu 7
circuit. nent.
Check the sensor.
108/2 - PID108/ Faulty signal from No limitation. Check cabling between - ENGINE,
2 charge air pressure control unit and compo- menu 6
sensor. nent.
Check the sensor.


tions and tic menu
compo-
nents
Code Flash J1587
108/3 - PID108/ Sensor boost pres- No limitation. Check cabling between D794/A:29 ENGINE,
3 sure, short-circuited control unit and compo- menu 6
to voltage. nent.
Check the sensor.
108/4 - PID108/ Sensor boost pres- No limitation. Check cabling between D794/A:29 ENGINE,
4 sure, short-circuited control unit and compo- menu 6
to frame ground or nent.
open circuit. Check the sensor.
110/0 6.1 PID110/ High coolant tem- No limitation. Check coolant level. - ENGINE,
0 perature. Check that radiator is menu 7
clean.
Check thermostat.
pansion tank.
coolant system.
Check the sensor.
110/4 3.3 PID110/ Sensor coolant Preheating is acti- Check cabling between D794/B:27 ENGINE,
4 temperature, short- vated even if en- control unit and compo- menu 7
circuited to ground. gine is warm. nent.
Check the sensor.
110/5 3.3 PID110/ Sensor coolant Preheating is acti- Check cabling between D794/B:27 ENGINE,
5 temperature, cable vated even if en- control unit and compo- menu 7
open circuit. gine is warm. nent.
Check the sensor.
111/1 2.2 PID111/ Low coolant level. No limitation. Check the coolant level, - -
1 top up if needed.
Check the sensor.
158/1 3.9 PID158/ Low battery volt- Engine may be dif- Check and charge the D794/B:57, -
1 age. ficult to start. batteries. B:60
Check the alternator.
Check the battery ca-
bles.
164/0 - PID164/ High fuel pressure. No limitation. Check the fuel pump. - -
0 Check the sensor.


tions and tic menu
compo-
nents
Code Flash J1587
164/2 - PID164/ Faulty signal from Engine speed limit- Check cabling between D794/B:16 -
2 fuel pressure sen- ed to 1100 rpm. control unit and compo-
sor. nent.
Check the sensor.
164/4 - PID164/ Sensor fuel pres- Engine speed limit- Check cabling between D794/B:16 -
4 sure, short-circuited ed to 1100 rpm. control unit and compo-
to ground. nent.
Check the sensor.
164/5 - PID164/ Sensor fuel pres- Engine speed limit- Check cabling between D794/B:16 -
5 sure, open circuit. ed to 1100 rpm. control unit and compo-
nent.
Check the sensor.
190/0 2.6 PID190/ Engine rpm too No limitation. Ease off throttle or select - -
0 high. higher gear.
626/3 5.4 PID45/3 Preheating relay, Preheating cannot Check cabling between D794/B:25 ENGINE,
short-circuited to be activated. control unit and compo- menu 5
voltage. White smoke at nent.
cold-start. Check the relay.
Start problems in
cold weather.
626/4 5.4 PID45/4 Preheating relay, Preheating relay is Check cabling between D794/B:25 ENGINE,
short-circuited to activated constant- control unit and compo- menu 5
ground. ly. Fuse for pre- nent.
heating may blow. Check the relay.
626/5 5.4 PID45/5 Preheating relay, Preheating cannot Check cabling between D794/B:25 ENGINE,
open circuit or de- be activated. control unit and compo- menu 5
fective component. White smoke at nent.
cold-start. Check the relay.
Start problems in
cold weather.
629/3 9.9 SID254/ Engine control unit The engine will not Change the control unit. - -
3 (D794), internal start.
fault.
629/8 9.9 SID254/ Engine control unit The engine will not Change the control unit. - -
8 (D794), internal start.
fault.
629/ 9.9 SID254/ Engine control unit The engine will not Change the control unit. - -
12 12 (D794), internal start.
fault.


tions and tic menu
compo-
nents
Code Flash J1587
636/2 9.9 SID21/3 Faulty signal from Engine takes long- Check cabling between D794/A:45, -
camshaft speed er time to start than control unit and compo- A:46
sensor. normal. Engine nent.
runs normally Check the sensor.
when it has started.
636/3 2.5 SID21/3 Sensor rpm cam- Engine takes long- Check cabling between D794/A:45, -
shaft, no signal. er time to start than control unit and compo- A:46
normal. Engine nent.
636/8 2.5 SID21/8 Sensor engine rpm, Engine takes long- Check cabling between D794/A:45, -
camshaft, abnormal er time to start than control unit and compo- A:46
frequency. normal. Engine nent.
637/2 2.4 SID22/2 Faulty signal from Engine is difficult to Check cabling between D794/A:37, ENGINE,
engine speed sen- start and runs control unit and compo- A:38 menu 2
sor, flywheel. rough, if it starts. nent.
Check the sensor.
637/3 2.4 SID22/3 Sensor engine rpm, Engine is difficult to Check cabling between D794/A:37, ENGINE,
flywheel, abnormal start and runs control unit and compo- A:38 menu 2
frequency. rough, if it starts. nent.
Check the sensor.
637/8 2.4 SID22/8 Sensor engine rpm, Engine is difficult to Check cabling between D794/A:37, ENGINE,
flywheel, abnormal start and runs control unit and compo- A:38 menu 2
frequency. rough, if it starts. nent.
Check that the sensor is
connected correctly.
639/2 6.5 SID231/ Communication er- Engine off: engine Use diagnostic menu to D794/B:51, CAN/POW-
2 ror with Engine con- cannot be started. find incorrect segment. B:55 ER, menu 3
trol unit (D794), Engine on: engine Check cabling between
configuration error. goes to idle and control unit and compo-
can only be nent.
stopped by using Check the control unit.
the emergency
stop.
639/2 9.9 SID240/ Communication er- It may not be possi- Re-program the control - -
2 ror with Engine con- ble to start the en- unit.
trol unit (D794), gine.


tions and tic menu
compo-
nents
Code Flash J1587
639/7 9.9 SID240/ Communication er- It may not be possi- Re-program the control - -
7 ror with Engine con- ble to start the en- unit.
639/9 6.4 PSID20 Communication er- Instruments and Use diagnostic menu to - -
1675/ 1/9 ror with Engine con- controls do not find incorrect segment.
9 trol unit (D794), work. Check cabling between
configuration error. control unit and compo-
nent.
Check the control unit.
639/ 9.9 SID240/ Communication er- It may not be possi- Re-program the control - -
11 11 ror with Engine con- ble to start the en- unit.
639/ 9.9 SID240/ Communication er- It may not be possi- Re-program the control - -
14 14 ror with Engine con- ble to start the en- unit.
651/3 7.1 SID1/3 Electric failure, in- Engine runs on 5 Check cabling between D794/A:24 -
jector cylinder 1. cylinders, sounds control unit and compo-
rough and has re- nent.
651/7 7.1 SID1/7 Incorrect compres- Runs rough at low Check fuel pressure. D794/A:24 -
sion or defective in- rpms and low load. Check valve clearance.
jector cylinder 1.
Check cabling between
control unit and compo-
nent.
Check the injector.
Perform compression
test and check cylinder 1.


tions and tic menu
compo-
nents
Code Flash J1587
651/ 7.1 SID1/12 Electric failure, in- Engine runs on 5 Check cabling between D794/A:24 -
12 jector cylinder 1. cylinders, sounds control unit and compo-
jector cylinder 2.
nent.
Check the injector.
Perform compression


tions and tic menu
compo-
nents
Code Flash J1587
jector cylinder 3.
nent.
Check the injector.
Perform compression
jector cylinder 4.
nent.
Check the injector.
Perform compression


tions and tic menu
compo-
nents
Code Flash J1587
655/7 7.5 SID5/7 Incorrect compres- Engine runs on 5 Check that cabling to the D794/A:48 -
sion or defective in- cylinders, sounds injectors is not damaged.
jector cylinder 5. rough and has re- Check cabling between
duced power. control unit and compo-
nent.
Check the injector.
Perform compression


tions and tic menu
compo-
nents
Code Flash J1587
jector cylinder 6.
nent.
Check the injector.
Perform compression
656/ 7.6 SID6/12 Electric failure, in- Engine runs on 5 Check cabling between D794/A:36, -
12 jector cylinder 6. cylinders, sounds control unit and compo- A:40
677/3 6.3 SID39/3 Starter motor relay, The engine will not Check cabling between D794/B:29 ENGINE,
1675/ short-circuited to start. control unit and compo- menu 5
3 voltage. Engine starts im- nent.
mediately when ig- Check the relay.
nition is turned on.
1675/ short-circuited to start. control unit and compo- menu 5
4 ground. nent.
Check the relay.
1675/ open circuit. start. control unit and compo- menu 5
5 nent.
Check the relay.
679/0 - PSID97/ Faulty signal from Engine speed limit- Check cabling between - -
0 pressure relief ed to 1100 rpm. control unit and compo-
valve. Reduced engine nent.
power. Check the component.
679/3 - SID42/3 Pressure relief Engine speed limit- Check cabling between - -
valve, shorted to 1100 rpm. control unit and compo-


tions and tic menu
compo-
nents
Code Flash J1587
valve, shorted to 1100 rpm. control unit and compo-
circuited to ground. nent.
valve, open circuit. ed to 1100 rpm. control unit and compo-
nent.
679/7 - PSID97/ Pressure relief Engine speed limit- Check cabling between - -
7 valve, mechanical ed to 1100 rpm. control unit and compo-
defect. Reduced engine nent.
679/ - PSID97/ Pressure relief Engine speed limit- Check cabling between - -
11 11 valve, unidentified ed to 1100 rpm. control unit and compo-
problem. Reduced engine nent.
679/ - PSID97/ Pressure relief Engine speed limit- Check cabling between - -
14 14 valve, defective ed to 1100 rpm. control unit and compo-
component. Reduced engine nent.
729/3 - SID70/3 Sensor preheating, Fuse blows. Check cabling between D794/B:31 -
short-circuited to control unit and compo-
voltage. nent.
729/4 - SID70/4 Sensor preheating, Engine difficult to Check cabling between D794/B:31 -
short-circuited to start in cold weath- control unit and compo-
ground. er. nent.
729/5 - SID70/5 Sensor preheating, Engine difficult to Check cabling between D794/B:31 -
open circuit. start in cold weath- control unit and compo-
er. nent.
1079/ 9.3 SID 232/ Reference voltage No limitation. Check cabling between D794/B:17 -
3 3 5 V no. 1 to sensor, control unit and compo-
voltage. Check the sensor.


tions and tic menu
compo-
nents
Code Flash J1587
1079/ 9.3 SID 232/ Reference voltage No limitation. Check cabling between D794/B:17 -
1080/ - SID 211/ Reference voltage No limitation. Check cabling between D794/A:7 -
voltage. Check the sensor.
1080/ - SID 211/ Reference voltage No limitation. Check cabling between D794/A:7 -
1239/ - PSID Too high fuel pres- Engine speed limit- Check fuel feed. - -
0 96/0 sure. ed to 1100 rpm.
High engine power.
(Powerful engine)
1239/ - PSID Too low fuel pres- Engine speed limit- Check fuel filter, replace - -
1 96/1 sure. ed to 1100 rpm. if necessary.
Reduced engine Check fuel feed.
power.
1239/ - PSID Sensor fuel pres- Engine speed limit- Check cabling between D794/B:16 -
4 96/4 sure, short-circuited ed to 1100 rpm. control unit and compo-
to ground. Reduced engine nent.
power. Check the sensor.
Engine starting dif-
ficulty.
1239/ - PSID Sensor fuel pres- Engine speed limit- Check cabling between D794/B:16 -
7 96/7 sure, mechanical ed to 1100 rpm. control unit and compo-
defect. Reduced engine nent.
power. Check the sensor.
ficulty.
1239/ - PSID Sensor fuel pres- Engine speed limit- Check the sensor. - -
12 96/12 sure, defective ed to 1100 rpm.
component. Reduced engine
power.
ficulty.


tions and tic menu
compo-
nents
Code Flash J1587
2791/ - PPID19/ Internal EGR, short- Internal EGR not Check cabling between D794/B:30 -
3 3 circuited to voltage. working. control unit and compo-
nent.
2791/ - PPID19/ Internal EGR, short- Internal EGR not Check cabling between D794/B:30 -
4 4 circuited to ground. working. control unit and compo-
nent.
2791/ - PPID19/ Internal EGR, open Internal EGR not Check cabling between D794/B:30 -
5 5 circuit. working. control unit and compo-
nent.
2791/ - PPID19/ Internal EGR, me- Internal EGR not Check sensor boost D794/B:30 -
7 7 chanical defect. working. pressure.
Check the component
(IEGR)
Contact Volvo Penta
workshop for more infor-
mation.
52019 6.8 PPID6/5 Sensor piston cool- No limitation. Check cabling between D794/B:14 -
2/5 ing pressure, short- control unit and compo-
circuiting to voltage, nent.
ground, or open cir- Check the sensor.
cuit.
- - PPID High fuel pressure. Engine speed limit- Check fuel feed. - -
435/0 ed to 1100 rpm.
High engine power.
(Powerful engine)
- - PPID Low fuel pressure. Engine speed limit- Check fuel filter, replace - -
435/4 ed to 1100 rpm. if necessary.
Reduced engine Check fuel feed.
power.

Error codes (Volvo TAD950VE and

page
–
TAD952VE engines)
tions and tic menu
compo-
nents
Code J1587
94 / 1 PID94 Fuel pressure. - Check if pressure can be D794 -
• Low feed built up with the hand
pressure. pump.
Check the fuel filter.
Check the fuel pre-filter.
94 / 3 PID94 Fuel pressure - Check that the fuel pres- D794 -

sensor. sure sensor connector is
• Short properly connected.
circuited to Check that the fuel pres-
plus (+) or mi- sure sensor wiring is not
nus (-). damaged.
• Open circuit. Check that the fuel pres-
sure sensor is properly in-
stalled.
Check the function of the
fuel pressure sensor.
94 / 5 PID94 Fuel pressure - Check that the fuel pres- D794 -

sensor. sure sensor connector is
• Short properly connected.
circuited to Check that the fuel pres-
plus (+) or mi- sure sensor wiring is not
nus (-). damaged.
• Open circuit. Check that the fuel pres-
sure sensor is properly in-
stalled.
fuel pressure sensor.
97 / 0 PID97 Water in fuel. - Drain the fuel pre-filter. D794 -
97 / 3 PID97 Water in fuel. - Check the indicator wiring D794 -

• Short circuit for short circuit and open
circuit.
• Open circuit.
• Indicator er- indicator and replace it if
ror. necessary.
98 / 1 PID98 Oil level Warning indica- Check oil level. D794 ENGINE,
• Low oil level. tion. menu 6


tions and tic menu
compo-
nents
Code J1587
98 / 5 PID98 Oil level - Check that the oil level sen- D794 ENGINE,
• Short circuit. sor wiring is not damaged. menu 6
• Open circuit. Check that the oil level sen-

sor is connected correctly.
• Indicator er-
ror.
100 / 1 PID100 Oil pressure The engine con- Check oil level. D794 ENGINE,
• Oil pressure trol unit limits en- Check that oil filters are not menu 6
is too low. gine output. clogged.
Check the system pressure
valves and the safety valve
in the oil system.
oil pressure sensor.
100 / 3 PID100 Oil pressure sen- - Check that the oil pressure D794 ENGINE,
sor sensor wiring is not dam- menu 6
• Short aged.
circuited to Check that the oil pressure
plus (+) or mi- sensor is connected cor-
nus (-). rectly.
• Open circuit.
100 / 5 PID100 Oil pressure sen- - Check that the oil pressure D794 ENGINE,
sor sensor wiring is not dam- menu 6
• Short aged.
circuited to Check that the oil pressure
plus (+) or mi- sensor is connected cor-
nus (-). rectly.
• Open circuit.
105 / 0 PID105 Charge air tem- The engine con- Check coolant level. D794 ENGINE,
perature trol unit limits en- Check the intercooler menu 7
• Charge air gine output. (cleanliness).
temperature Check the function of the
too high. charge air temperature
sensor.
thermostat.


tions and tic menu
compo-
nents
Code J1587
105 / 4 PID105 Charge air tem- - Check that the charge air D794 ENGINE,
perature sensor temperature sensor con- menu 7
• Short nector is properly connect-
circuited to ed.
plus (+) or mi- Check that the charge air
nus (-). temperature sensor wiring
• Open circuit. is not damaged.
Check that the charge air
temperature sensor is
properly installed.
charge air temperature
sensor.
105 / 5 PID105 Charge air tem- - Check that the charge air D794 ENGINE,
perature sensor temperature sensor con- menu 7
• Short nector is properly connect-
circuited to ed.
plus (+) or mi- Check that the charge air
nus (-). temperature sensor wiring
• Open circuit. is not damaged.
Check that the charge air
temperature sensor is
properly installed.
charge air temperature
sensor.
106 / 0 PID106 Boost pressure The engine con- Check the function of the D794 ENGINE,
• Boost pres- trol unit limits en- turbocharger. menu 6
sure too high. gine output. Check the function of the
boost pressure sensor.
Check fuel quantity/injec-
tor.


tions and tic menu
compo-
nents
Code J1587
106 / 3 PID106 Boost pressure The engine jerks Check that the charge air D794 ENGINE,
sensor more than normal pressure sensor connector menu 6
• Short during accelera- is properly connected.
circuited to tion or load in- Check that the charge air
plus (+) or mi- crease. pressure sensor wiring is
nus (-). not damaged.
• Open circuit. Check that the charge air
pressure sensor is properly
installed.
106 / 5 PID106 Boost pressure The engine jerks Check that the charge air D794 ENGINE,
sensor more than normal pressure sensor connector menu 6
• Short during accelera- is properly connected.
circuited to tion or load in- Check that the charge air
plus (+) or mi- crease. pressure sensor wiring is
• Open circuit. Check that the charge air
pressure sensor is properly
installed.
110 / 0 PID110 Coolant tempera- The engine con- Check coolant level. D794 ENGINE,
ture trol unit limits en- Check the intercooler menu 7
• Coolant tem- gine output. (cleanliness).
perature too Check if there’s air in cool-
high. ant system.
pansion tank.
coolant temperature sen-
sor.
thermostat.


tions and tic menu
compo-
nents
Code J1587
110 / 4 PID110 Coolant tempera- Preheating is acti- Check that the coolant tem- D794 ENGINE,
ture sensor. vated even if the perature sensor connector menu 7
• Short engine is warm. is properly connected.
circuited to The engine is diffi- Check that the coolant tem-
plus (+) or mi- cult to start. perature sensor wiring is
• Open circuit. Check that the coolant tem-
perature sensor is properly
installed.
sor.
110 / 5 PID110 Coolant tempera- Preheating is acti- Check that the coolant tem- D794 ENGINE,
ture sensor vated even if the perature sensor connector menu 7
• Short engine is warm. is properly connected.
circuited to The engine is diffi- Check that the coolant tem-
plus (+) or mi- cult to start. perature sensor wiring is
• Open circuit. Check that the coolant tem-
perature sensor is properly
installed.
sor.
111 / 1 PID111 Coolant level The engine con- Check coolant level. D794 -
• Low coolant trol unit limits en- Check the function of the
level. gine output. coolant level switch.
Engine stops.
111 / 3 PID111 Coolant tempera- - Check coolant level. D794 -

ture sensor Check the function of the
• Short coolant level switch.
circuited to
plus (+).
• Sensor error.
153 / 0 PID153 Crankcase venti- Engine will shut Check whether crankcase D794 -
lation pressure down. ventilation is clogged.
• High crank- Check for wear or damage
case ventila- to the cylinder liner, piston
tion pressure. or piston rings.


tions and tic menu
compo-
nents
Code J1587
153 / 3 PID153 Crankcase venti- - Check that the crankcase D794 -
lation pressure ventilation pressure sensor
sensor connector is properly con-
• Short nected.
circuited to Check that the crankcase
plus (+) or mi- ventilation pressure sensor
nus (-). wiring is not damaged.
• Open circuit. Check that the crankcase
ventilation pressure sensor
is properly installed.
crankcase ventilation pres-
sure sensor.
153 / 5 PID153 Crankcase venti- - Check that the crankcase D794 -

lation pressure ventilation pressure sensor
sensor connector is properly con-
• Short nected.
circuited to Check that the crankcase
plus (+) or mi- ventilation pressure sensor
nus (-). wiring is not damaged.
• Open circuit. Check that the crankcase
ventilation pressure sensor
is properly installed.
crankcase ventilation pres-
sure sensor.
158 / 1 PID158 Battery voltage, - Check the supply voltage D794 -

EMS from the control unit.
• Alternator er-
ror.
• Battery/bat-
tery cable er-
ror.
175 / 0 PID175 Oil temperature The engine con- Check oil level. D794 ENGINE,
• Oil tempera- trol unit limits en- Check the oil temperature. menu 7
ture too high. gine output.
oil temperature sensor.


tions and tic menu
compo-
nents
Code J1587
175 / 4 PID175 Oil temperature - Check that the oil tempera- D794 ENGINE,
sensor ture sensor wiring is not menu 7
• Short damaged.
circuited to Check that the oil tempera-
plus (+) or mi- ture sensor is connected
nus (-). correctly.
• Open circuit.
175 / 5 PID175 Oil temperature - Check that the oil tempera- D794 ENGINE,
sensor ture sensor wiring is not menu 7
• Short damaged.
circuited to Check that the oil tempera-
plus (+) or mi- ture sensor is connected
nus (-). correctly.
• Open circuit.
190 / 0 PID190 Engine rpm - After stopping the engine, D794 ENGINE,
• Rpm too troubleshoot the cause of menu 2
high. high rpm.
608 / 3 PPID132 Rpm potentiome- Engine goes to Check that the potentiome- D794 -
ter connected to idle. ter is connected correctly.
CIU Rpm "freezes". Check that the potentiome-
• Short ter wiring is not damaged.
circuited to Check the function of the
plus (+) or mi- potentiometer.
nus (-).
• Sensor error.
• Short ter wiring is not damaged.
circuited to Check the function of the
plus (+) or mi- potentiometer.
nus (-).
• Sensor error.
• EMS2 has no ter wiring is not damaged.
signal from Check the function of the
the rpm po- potentiometer.
tentiometer.


tions and tic menu
compo-
nents
Code J1587
608 / 9 PPID98 Engine synchro- - Check that the 8-pin con- D794 -
nisation confirma- nector is not damaged.
tion Check that the wiring be-
• Communica- tween CIU/DCU and the
tion error. engine control unit is not
damaged.
608 / 12 SID250 Data link J1587 - Check that the 8-pin con- D794 -
error. nector is not damaged.
Check that the wiring be-
tween CIU/DCU and the
engine control unit is not
damaged.
626 / 3 PID45 Preheating relay Preheating can- Check that the wiring to the D794 -
• Short not be activated. relay input is not damaged.
circuited to White exhaust at Check the function of the
plus (+) or mi- cold start. relay.
nus (-). Starting problems
• Open circuit. in cold climate.
626 / 4 PID45 Preheating relay Preheating is con- Check that the wiring to the D794 -
• Short tinually engaged. relay input is not damaged.
circuited to Preheating fuse Check the function of the
plus (+) or mi- blows. relay.
nus (-).
• Open circuit.
626 / 5 PID45 Preheating relay Preheating can- Check that the wiring to the D794 -
• Short not be activated. relay input is not damaged.
circuited to White exhaust at Check the function of the
plus (+) or mi- cold start. relay.
nus (-). Starting problems
• Open circuit. in cold climate.
629 / 3 SID254 CIU control unit CIU resumes fac- Reprogram the unit. D794 -
error tory settings.
• EEPROM, Engine goes to
CIU error. idle.
• Flash memo- Engine cannot be
ry, CIU error. started.
• CIU control
unit error.


tions and tic menu
compo-
nents
Code J1587
CIU error. idle.
• CIU control
unit error.
CIU error. idle.
• CIU control
unit error.
630 / All SID253 Batch memory Engine cannot be Reprogram the unit. D794 -
EEPROM, EMS 2 started.
• Internal con-
trol unit error.
• Error during
program-
ming.
636 / 2 SID21 Rpm sensor, cam Engine takes Check that the rpm sensor D794 -
gear longer to start connector is properly con-
• Abnormal fre- than normal. En- nected.
quency. gine runs normal- Check that the rpm sensor
ly once started, wiring is not damaged.
• No signal. but only uses fly-
• Sensor error. wheel rpm sen- Check that the rpm sensor
sor. is properly installed in the
upper timing cover.
rpm sensor.


tions and tic menu
compo-
nents
Code J1587
• No signal.
but only uses fly-
sor. is properly installed in the
upper timing cover.
rpm sensor.
• No signal. but only uses fly-
is properly installed in the
sor.
upper timing cover.
rpm sensor.
637 / 2 SID22 Rpm sensor, fly- Engine extremely Check that the sensor con- D794 -
wheel. difficult to start nector is properly connect-
• No signal. and runs rough if ed.
it starts. Check that the rpm sensor
• Abnormal fre-
quency. Only uses rpm wiring is not damaged.
sensor for cam Check that the rpm sensor
• Intermittent gear. is properly installed in the
signal from
sensor. flywheel cover.
• Sensor error. Check the function of the

rpm sensor.
637 / 3 SID22 Rpm sensor, fly- Engine runs with Check that the sensor con- D794 -
wheel. inexact timing, nector is properly connect-
• No signal. which increases ed.
fuel consumption Check that the rpm sensor
• Abnormal fre- and exhaust
quency. wiring is not damaged.
emissions. Cylin-
• Intermittent Check that the rpm sensor
ders’ balance
signal from is properly installed in the
does not work,
which generates a
• Sensor error. risk of rough run- Check the function of the
ning. rpm sensor.


tions and tic menu
compo-
nents
Code J1587
637 / 8 SID22 Rpm sensor, fly- Engine extremely Check that the sensor con- D794 -
wheel. difficult to start nector is properly connect-
• No signal. and runs rough if ed.
it starts. Check that the rpm sensor
• Abnormal fre-
quency. Only uses rpm wiring is not damaged.
sensor for cam Check that the rpm sensor
• Intermittent gear. is properly installed in the
signal from
• Sensor error. Check the function of the

rpm sensor.
639 / 2 SID231 Data link (CAN), The engine can- Check that the 8-pin con- D794 -
CIU not be started or, nector is not damaged.
• Data link er- if it can be started, Check that the wiring be-
ror (CAN), only stops with tween CIU and the engine
CIU. the exterior stop control unit is not dam-
button or auxiliary aged.
stop for EMS.
Instrument and
warning lamps
stop working.
639 / 2 SID240 EMS memory er- The engine will Reprogram the unit. D794 -
ror not start. Replace the control unit
• Engine con- (EMS).
trol unit
(EMS) mem-
ory error.
trol unit
(EMS) mem-
ory error.
trol unit
(EMS) mem-
ory error.


tions and tic menu
compo-
nents
Code J1587
trol unit
(EMS) mem-
ory error.
651 - 656 / SID1 - 6 Injectors, cylin- Engine runs on 5 Check that the unit injector D794 -
2 der #1 - 6 cylinders. wiring is not damaged.
• Electrical er- Abnormal noise. Check that the injector con-
ror. Impaired perform- nections are not damaged.
• Compres- ance. Check the fuel feed pres-
sion or injec- Defective injector sure.
tor error. deactivated; "limp Check valve clearance.
home" with other Perform a compression
injectors. test and check cylinders #1
- 6.
- 6.
- 6.


tions and tic menu
compo-
nents
Code J1587
- 6.
651 - 656 / SID1 - 6 Injectors, cylin- - Check that the unit injector D794 -
7 der #1 - 6 wiring is not damaged.
• Electrical er- Check that the injector con-
ror. nections are not damaged.
• Compres- Check the fuel feed pres-
sion or injec- sure.
tor error. Check valve clearance.
Perform a compression
test and check cylinders #1
- 6.
- 6.


tions and tic menu
compo-
nents
Code J1587
- 6.
677 / 3 PPID3 Start output / Engine cannot be Check that start key con- D794 -
Starter motor re- started. nections is not damaged.
lay Check that the start key
• Short wiring is not damaged.
circuited to
plus (+) or mi-
nus (-).
Activated too
long.
677 / 4 PPID3 Start output / Engine starts im- Check that start key con- D794 -
Starter motor re- mediately when nections is not damaged.
lay the ignition is Check that the start key
• Short switched on. wiring is not damaged.
circuited to
plus (+) or mi-
nus (-).
Activated too
long.
677 / 5 PPID3 Start output / Engine cannot be Check that start key con- D794 -
Starter motor re- started. nections is not damaged.
lay Check that the start key
• Short wiring is not damaged.
circuited to
plus (+) or mi-
nus (-).
Activated too
long.


tions and tic menu
compo-
nents
Code J1587
1079 / 3 SID232 Voltage feed to Incorrect oil pres- Check that the oil pressure D794 -
sensor sure and charge and charge air pressure
• Short circuit. air pressure sen- sensor wiring is not dam-
sor values. aged.
• Sensor error.
Error code for oil Check the oil pressure and
pressure and charge air pressure sen-
charge air pres- sors.
sure sensors.
Low output.
Oil pressure and
boost pressure
gauges point to 0
in the instrument
panel.
1079 / 4 SID232 Voltage feed to Incorrect oil pres- Check that the oil pressure D794 -
sensor sure and charge and charge air pressure
• Short circuit. air pressure sen- sensor wiring is not dam-
sor values. aged.
• Sensor error.
Error code for oil Check the oil pressure and
pressure and charge air pressure sen-
charge air pres- sors.
sure sensors.
Low output.
Oil pressure and
boost pressure
gauges point to 0
in the instrument
panel.
2791 / 3 PPID19 Internal EGR The engine con- Check the wiring (boost D794 -
• Wiring error trol unit limits en- pressure sensor).
(boost pres- gine output. Contact an authorised Vol-
sure sensor). IEGR cannot be vo Penta workshop.
• Mechanical activated. Check the IEGR.
error on IE-
GR.


tions and tic menu
compo-
nents
Code J1587
error on IE-
GR.
error on IE-
GR.
2791 / 7 PPID19 Internal EGR Could damage Check the wiring (boost D794 -
• Mechanical the turbine wheel pressure sensor).
error on IE- of the turbocharg- Contact an authorised Vol-
GR. er and increase vo Penta workshop.
force and emis-
Check the IEGR.
sions.
520194 / 3 PPID4 Start input CIU Engine cannot be Check that start key con- D794 -
• Short started. nections is not damaged.
circuited to Engine starts im- Check that the start key
minus (-). mediately when wiring is not damaged.
• Activated too the ignition is
long. switched on.
520194 / 4 PPID4 Start input CIU Engine cannot be Check that start key con- D794 -
• Short started. nections is not damaged.
circuited to Engine starts im- Check that the start key
minus (-). mediately when wiring is not damaged.
• Activated too the ignition is
long. switched on.
520195 / 4 PPID6 Stop input EMS The engine can Check that the connections D794 -
• Short only be stopped and wiring are not dam-
circuited to with the auxiliary aged.
minus (-). stop.
• Activated too
long.

Error codes (Volvo TAD1250VE

page
–
engine)
tions and tic menu
compo-
nents
Code Flash J1587
94/ 3.6 PID94/ Fuel pressure No limitation. Check cabling be- D794/B:16 -
FMI FMI sensor, short tween control unit and
circuited to volt- component.
age, ground, or Check the sensor.
open circuit.
94/ 3.8 PID94/ Low fuel pres- No limitation. Change fuel filter. - -
FMI FMI sure (feed). Change fuel pre-filter.
Check if pressure can
be built up with the
hand pump.
97/1 2.1 PID97/1 Water in fuel. No limitation. Drain water separator. - -

Clean metal filter in the
fuel feed’s hose con-
nection on the engine.
Check fuel filter and
fuel pre-filter.
97/3 2.9 PID97/3 Water-in-fuel No limitation. Check cabling be- D794/B:8 -

sensor short tween control unit and
circuited to component.
ground or open Check the sensor.
circuit.
98/ 5.7 PID98/ Low oil level. No limitation. Check oil level. - ENGINE,
FMI FMI menu 6
98/ 5.9 PID98/ Oil level sensor, No limitation. Check cabling be- D794/B:3, ENGINE,
FMI FMI short circuited to tween control unit and B:4, A:31 menu 6
voltage, ground, component.
or open circuit. Check the sensor.
100/1 6.6 PID100/ Low engine oil Engine will shut Check oil level. - ENGINE,
1 pressure. down. Change oil filter. menu 6
Check the system

pressure valves and
the safety valve in the
lubrication system.
Check the sensor.


tions and tic menu
compo-
nents
Code Flash J1587
100/3 3.1 PID100/ Sensor oil pres- No limitation. Check cabling be- D794/B:11 ENGINE,
3 sure, cable short tween control unit and menu 6
circuited to sup- component.
ply voltage. Check the sensor.
100/4 3.1 PID100/ Oil pressure No limitation. Check cabling be- D794/B:11 ENGINE,
4 sensor, open cir- tween control unit and menu 6
cuit or short cir- component.
cuit to ground. Check the sensor.
102/0 3.5 PID102/ Boost pressure No limitation. Check the turbocharg- - ENGINE,
0 too high. er. menu 6
Check the sensor.
Check fuel quality and
injectors.
102/1 3.5 PID102/ Boost pressure Reduced engine Check the air filter. - ENGINE,
1 too low. power. Check the turbocharg- menu 6
er.
Check the sensor.
Check the fuel feed
pressure.
102/3 3.4 PID102/ Sensor boost The engine jerks Check cabling be- D794/A:22 ENGINE,
3 pressure, cable more than normal tween control unit and menu 7
short-circuited to during acceleration component.
voltage. or load. Check the sensor.
102/4 3.4 PID102/ Boost pressure The engine jerks Check cabling be- D794/A:22 ENGINE,
4 sensor, cable more than normal tween control unit and menu 7
short circuited to during acceleration component.
ground or open or load. Check the sensor.
circuit.
105/0 6.2 PID105/ High charge-air Engine will shut Check coolant level. - ENGINE,
0 temperature. down. Check that the charge- menu 7
air cooler is clean.
Check thermostat.
Check the sensor.
105/3 3.2 PID105/ Charge air tem- No limitation. Check cabling be- D794/A:47 ENGINE,
3 perature sen- tween control unit and menu 7
sor, cable short component.
circuited to sup- Check the sensor.
ply voltage or
open circuit.


tions and tic menu
compo-
nents
Code Flash J1587
105/4 3.3 PID105/ Charge air tem- No limitation. Check cabling be- D794/A:47 ENGINE,
4 perature sen- tween control unit and menu 7
sor, cable short component.
circuited to Check the sensor.
ground or open
circuit.
106/ 3.4 PID106/ Boost pressure The engine jerks Check cabling be- D794/A:22 ENGINE,
FMI FMI sensor, short cir- more than normal tween control unit and menu 6
cuit to voltage, during acceleration component.
ground or open or load. Check the sensor.
circuit.
106/ 3.5 PID106/ High charge air No limitation. Check cabling be- - ENGINE,
FMI FMI pressure. tween control unit and menu 6
component.
Check the sensor.
110/0 6.1 PID110/ High coolant No limitation. Check coolant level. - ENGINE,
0 temperature. Check that radiator is menu 7
clean.
Check thermostat.
Check the cap on the
expansion tank.
coolant system.
Check the sensor.
110/3 3.3 PID110/ Coolant temper- Preheating is acti- Check cabling be- D794/B:27 ENGINE,
3 ature sensor, ca- vated even if engine tween control unit and menu 7
ble short is warm. component.
circuited to sup- Check the sensor.
ply voltage or
open circuit.
110/4 3.3 PID110/ Coolant temper- Preheating is acti- Check cabling be- D794/B:27 ENGINE,
4 ature sensor, ca- vated even if engine tween control unit and menu 7
ble short is warm. component.
circuited to Check the sensor.
ground.
111/1 2.2 PID111/ Low coolant lev- No limitation. Check the coolant lev- - -
1 el. el, top up if needed.
Check the sensor.


tions and tic menu
compo-
nents
Code Flash J1587
111/ 2.3 PID111/ Coolant level No limitation. Check cabling be- D794/B:23 -
FMI FMI sensor, short tween control unit and
age. Check the sensor.
153/ 7.7 PID153/ High crankcase No limitation. Clean the crankcase - -

FMI FMI ventilation pres- ventilation.
sure. Check for wear on the
cylinder liner, piston
and piston rings.
153/ 7.7 PID153/ Crankcase ven- No limitation. Check cabling be- D794/B:28 -
FMI FMI tilation pressure tween control unit and
sensor, short cir- component.
cuit to voltage, Check the sensor.
ground or open
circuit.
158/ 3.9 PID158/ Low battery volt- Engine may be diffi- Check and charge the - -
FMI FMI age. cult to start. batteries.
Check the alternator.
Check the battery ca-
bles.
172/ 7.9 PID172/ Intake air tem- No limitation. Check cabling be- D794/A:47 ENGINE,
FMI FMI perature sen- tween control unit and menu 7
sor, short circuit component.
to voltage, Check the sensor.
ground, or open
circuit.
175/0 5.8 PID175/ High engine oil Reduced engine Check oil level. - ENGINE,
0 temperature. power. Check the lubrication menu 7
system’s thermostat.
Check the sensor.
175/3 3.7 PID175/ Oil temperature No limitation. Check cabling be- D794/A:31, ENGINE,
3 sensor, cable tween control unit and B:3, B:4 menu 7
short circuited to component.
supply voltage Check the sensor.
or open circuit.
175/4 3.7 PID175/ Oil temperature No limitation. Check cabling be- D794/A:31, ENGINE,
4 sensor, cable tween control unit and B:3, B:4 menu 7
short circuited to component.


tions and tic menu
compo-
nents
Code Flash J1587
190/ 2.6 PID190/ Engine rpm too No limitation. Ease off throttle or se- - -
FMI FMI high. lect higher gear.
608/ - PPID98/ Signal error for No limitation. Check the CAN bus - CAN/POW-
FMI FMI start and stop. drivetrain. ER, menu 3
620/3 9.3 SID232/ Voltage feed to Several error codes Check cabling be- D794/B:17 -
1079/ 3 sensor, cable for sensor error. tween control unit and
2 short circuited to Reduced engine component.
voltage. power.
Incorrect instrument
values.
620/4 9.3 SID232/ Voltage feed to Several error codes Check cabling be- D794/B:17 -
1079/ 4 sensor, cable for sensor error. tween control unit and
3 short circuited to Reduced engine component.
ground. power.
Incorrect instrument
values.
626/3 5.4 PID45/3 Preheating re- Preheating cannot Check cabling be- D794/B:25 ENGINE,
lay, cable short be activated. tween control unit and menu 5
age. Check the relay.
626/4 5.4 PID45/4 Preheating re- Preheating is contin- Check cabling be- D794/B:25 ENGINE,
lay, cable short ually activated. tween control unit and menu 5
circuited to component.
ground. Check the relay.
626/5 5.4 PID45/5 Preheating re- Preheating cannot Check cabling be- D794/B:25 ENGINE,
lay, open circuit be activated. tween control unit and menu 5
on cable or de- component.
fective compo- Check the relay.
nent.
629/ 9.9 SID254/ Engine control The engine will not Change the control - -
FMI FMI unit (D794), in- start. unit.
ternal fault. Engine runs roughly.
630/ 9.9 SID253/ Engine control The engine will not Re-program the con- - -
FMI FMI unit (D794), start. trol unit.
memory error.


tions and tic menu
compo-
nents
Code Flash J1587
636/3 2.5 SID21/3 Sensor rpm Engine takes longer Check cabling be- D794/B:45, -
camshaft, no time to start than tween control unit and B:46
signal. normal. Engine runs component.
normally when it has Check the sensor.
started.
636/8 2.5 SID21/8 Sensor engine Engine takes longer Check cabling be- D794/B:45, -
rpm, camshaft, time to start than tween control unit and B:46
abnormal fre- normal. Engine runs component.
quency. normally when it has Check the sensor.
started.
637/2 2.4 SID22/2 Engine rpm sen- Engine is extremely Check cabling be- D794/B:37, ENGINE,
sor, flywheel, ir- difficult to start and tween control unit and B:38 menu 2
regular signal. runs rough, if it component.
starts. Check the sensor.
637/3 2.4 SID22/3 Sensor engine Engine is extremely Check cabling be- D794/B:37, ENGINE,
rpm, flywheel, difficult to start and tween control unit and B:38 menu 2
abnormal fre- runs rough, if it component.
quency. starts. Check the sensor.
637/8 2.4 SID22/8 Sensor engine Engine is extremely Check cabling be- D794/B:37, ENGINE,
rpm, flywheel, difficult to start and tween control unit and B:38 menu 2
abnormal fre- runs rough, if it component.
quency. starts. Check that the sensor
is connected correctly.
639/ 6.5 SID231/ Communication Engine off: engine Use diagnostic menu D794/B:51, CAN/POW-
FMI FMI error with En- cannot be started. to find incorrect seg- B:55 ER, menu 3
2017/ PSID20 gine control unit Engine on: engine ment.
FMI 1/FMI (D794), configu- goes to idle and can Check cabling be-
ration error. only be stopped by tween control unit and
using the emergen- component.
cy stop. Check the control unit.
639/ 6.4 SID231/ Communication Instruments and Use diagnostic menu - CAN/POW-
FMI FMI error with En- controls do not work. to find incorrect seg- ER, menu 3
gine control unit ment.
(D794), configu- Check cabling be-
ration error. tween control unit and
component.
639/ 9.9 SID240/ Engine control It may not be possi- Re-program the con- - -
FMI FMI unit, memory er- ble to start the en- trol unit.
ror. gine.


tions and tic menu
compo-
nents
Code Flash J1587
651/2 7.1 SID1/2 Electric failure, Engine runs on 5 Check cabling be- D794/A:20, -
injector cylinder cylinders, sounds tween control unit and A:24
1. rough and has re- component.
651/7 7.1 SID1/7 Incorrect com- Runs rough at low Check fuel pressure. D794/A:20, -
pression or de- rpms and low load. Check valve clear- A:24
fective injector ance.
cylinder 1.
Check cabling be-
tween control unit and
component.
Check the injector.
Perform compression
test and check cylinder
1.
651/ 7.1 SID1/11 Electric failure, Engine runs on 5 Check cabling be- D794/A:20, -
11 injector cylinder cylinders, sounds tween control unit and A:24


tions and tic menu
compo-
nents
Code Flash J1587
cylinder 2.
Check cabling be-
component.
Check the injector.
Perform compression
2.
652/ 123 SID2/11 Electric failure, Engine runs on 5 Check cabling be- D794/A:12, -
11 DTC injector cylinder cylinders, sounds tween control unit and A:16
7.2 2. rough and has re- component.


tions and tic menu
compo-
nents
Code Flash J1587
cylinder 3.
Check cabling be-
component.
Check the injector.
Perform compression
3.
654/2 140 SID4/2 Electric failure, Engine runs on 5 Check cabling be- D794/A:52, -
DTC injector cylinder cylinders, sounds tween control unit and A:56
7.4 4. rough and has re- component.


tions and tic menu
compo-
nents
Code Flash J1587
cylinder 4.
Check cabling be-
component.
Check the injector.
Perform compression
4.


tions and tic menu
compo-
nents
Code Flash J1587
655/7 7.5 SID5/7 Incorrect com- Engine runs on 5 Check that cabling to D794/A:44, -
pression or de- cylinders, sounds the injectors is not A:48
fective injector rough and has re- damaged.
cylinder 5. duced power. Check cabling be-
component.
Check the injector.
Perform compression
5.
duced power. Check the component.


tions and tic menu
compo-
nents
Code Flash J1587
cylinder 6.
Check cabling be-
component.
Check the injector.
Perform compression
6.
677/ 6.3 PPID3/ Starter motor re- The engine will not Check cabling be- D794/B:29 ENGINE,
FMI FMI lay, short circuit start. tween control unit and menu 5
SID39/ to voltage/ Engine starts imme- component.
FMI ground. diately when ignition Check the motor.
is turned on.
1485/ 5.1 PPID5/3 Main relay, ca- The instrument pan- Check cabling be- D794/A:8 -
3 ble short el loses voltage tween control unit and
circuited to volt- when the ignition component.
age. key is turned to the Check the relay.
start position. The
engine will not start.
2791/ - PPID19/ Internal EGR, No limitation. Check sensor boost D794/B:30 -

FMI FMI electrical or me- pressure.
chanical defect. Check the component
(IEGR)
Contact Volvo Penta
workshop for more in-
formation.
52019 6.8 PPID8/ Piston cooling No limitation. Check cabling be- D794/B:14 -
2/FMI FMI pressure sen- tween control unit and
sor, short component.
circuited to volt- Check the sensor.
age, ground, or
open circuit.
52019 6.7 PPID8/ Low piston cool- No limitation. Check that engine oil - -
2/FMI FMI ing pressure pressure is over 175
kPa.


tions and tic menu
compo-
nents
Code Flash J1587
52019 4.8 PPID4/ Stop input on the Engine cannot be Check cabling be- Volvo -
5/FMI FMI control unit short shut down. tween control unit and TAD1250VE:
circuited to component. D794/B:27
ground or open
circuit.

D Error codes – 2 Transmission 87
2 Transmission
mm mm mm mm mm mm
Error codes, transmission

page
–
Control unit transmission can generate two modes with reduced func-
tionality to protect the transmission in case of serious malfunctions:
• "Limp home", indicated in display with "LH".
In this mode only 1-2 gear in both directions can be used. If the
malfunction occurs in a higher gear then downshifting has to be
performed manually to 1st gear or 2nd.
• "Shutdown", indicated in display with "Sd".
In this mode, the transmission is in permanent neutral position as
there is no oil pressure to enable selection of a gear.
Connec-
tions and Diagnos-
Description Limitation Action
compo- tic menu
nents
Code
00/50 Memory error in con- Transmission locked in - - -
trol unit transmission. neutral (shutdown).



20/60 Sensor oil pressure Transmission locked in Check cabling between con- D793/A:2 - TRANSM,
(B253) indicates low neutral (shutdown). trol unit and component. B253 menu 10
oil pressure when Check the solenoid valve.
there should be pres-
sure.
20/61 The oil pressure sen- Transmission locked in Check cabling between con- D793/A:2 - TRANSM,
sor (B253) indicates oil neutral (shutdown). trol unit and component. B253 menu 10
pressure when there Check the solenoid valve.
should not be pres-
sure.
21/02 Solenoid valves VFS Transmission locked in Check cabling between the D793/D1 - TRANSM,
short-circuiting to volt- neutral (shutdown). control unit and the compo- Y6069, menu 7
age, ground, or open nent with diagnostic menu. D793/F2 -
circuit. Check the solenoid valve. Y6075
30/04 Low battery voltage. Control unit saves stored in- Check cabling to control unit. - CAN/POW-
formation to flash memory Check alternator, battery ER, menu
and restarts to clear memo- and cabling between battery 12
ry. and alternator.

88 D Error codes – 2 Transmission
Connec-
tions and Diagnos-
compo- tic menu
nents
Code
30/05 High battery voltage. Control unit receives re- Check voltage feed. - CAN/POW-
duced proportional control If auxiliary start equipment is ER, menu
precision depending on reconnected, disconnect it. 12
duced PWM work cycle.
31/00 Reference voltage Control unit receives re- Check voltage feed. - CAN/POW-
sensor 8 V, too low. duced sensor signals. Check the control unit. ER, menu
12
31/01 Reference voltage Control unit receives re- Check voltage feed. - CAN/POW-
sensor 8 V, too high. duced sensor signals. Check the control unit. ER, menu
12
40/06 Incorrect direction Control unit locks transmis- Check cabling to gear selec- - TRANSM,
from gear selector. sion in neutral. tor with regards to forward menu 2
and reverse signal.
41/06 Incorrect gear selec- Control unit doesn’t allow Check cabling to gear selec- - TRANSM,
tion from gear selector. change of range, however, tor with regards to signal menu 2
operation of machine is range.
possible.
42/04 Actual gear ratio too Control unit indicates that Check transmission with - TRANSM,
low. one or several clutches are purpose to understand if menu 6
slipping. and, if that is the case, which
clutch is slipping.
Check the set gear ratio for
the control unit.
42/05 Actual gear ratio too Control unit indicates that Check transmission with - TRANSM,
high. one or several clutches are purpose to understand if menu 6
slipping. and, if that is the case, which
clutch is slipping.
Check the set gear ratio for
the control unit.
43/03 Signal from Sensor en- Control unit indicates the Check cabling between con- D793/H3 - TRANSM,
gine rpm and oil tem- error. trol unit and component. B758/766 menu 10
perature transmission Check the sensor.
(B758/766) outside
valid interval.
43/07 Torque converter tem- Control unit indicates the Check transmission oil cool- D793/H3 - TRANSM,
perature exceeds 100 error to make operator er, clean as needed. B758/766 menu 10
°C. aware of the warning’s lev- Check the thermostat in the
el. transmission oil cooler.

Connec-
tions and Diagnos-
compo- tic menu
nents
Code
43/08 Torque converter tem- The control unit protects the Check transmission oil cool- D793/H3 - TRANSM,
perature exceeds 125 transmission and does not er, clean as needed. B758/766 menu 10
°C. allow the temperature in the Check the thermostat in the
torque converter to exceed transmission oil cooler.
the limit value.
The control unit locks the
transmission in neutral po-
sition, the engine is restrict-
ed to 50% of max. rpm.
44/10 Faulty signal for accel- - Use diagnostic menu to find - CAN/POW-
erator pedal position incorrect segment. ER, menu 4
from engine control
unit (D794).
45/05 Max. torque for inching - - - -

has been exceeded.
50/00 Sensor oil pressure Transmission in limp-home. Check cabling between con- D793/A:2 - TRANSM,
(B253), short-circuited trol unit and component. B253 menu 10
to ground. Check the sensor.
50/01 Sensor oil pressure Transmission in limp-home. Check cabling between con- D793/A:2 - TRANSM,
(B253), not connected trol unit and component. B253 menu 10
or open circuit. Check the sensor.
51/00 Sensor engine rpm The control unit limits the Check cabling between con- D793/H3 - TRANSM,
and oil temperature transmission’s temperature trol unit and component. B758/766 menu 10
transmission (B758/ measurement to the lowest Check the sensor.
766) short-circuited to value in its settings, which
ground. results in poor temperature
compensation.
51/01 Sensor engine rpm The control unit limits the Check cabling between con- D793/H3 - TRANSM,
and oil temperature transmission’s temperature trol unit and component. B758/766 menu 10
transmission (B758/ measurement to the highest Check the sensor.
766) not connected or value in its settings, which
open circuit. results in poor temperature
compensation.
52/00 Sensor oil temperature The control unit limits the Check cabling between con- D793/J3 - TRANSM,
(S221) short-circuited transmission’s temperature trol unit and component. S221 menu 10
to ground. measurement to the highest Check the sensor.
value in its settings, which
results in poor temperature
compensation.

Connec-
tions and Diagnos-
compo- tic menu
nents
Code
52/01 Sensor oil temperature The control unit limits the Check cabling between con- D793/J3 - TRANSM,
(S221) open circuit. transmission’s temperature trol unit and component. S221 menu 10
measurement to the highest Check the sensor.
value in its settings, which
results in poor temperature
compensation.
54/00 Reference voltage - Check cabling between con- - CAN/POW-

sensor 5 V short- trol unit and component. ER, menu
circuiting to frame Check the sensor. 12
ground.
54/01 Reference voltage - Check cabling between con- - CAN/POW-

sensor 5 V open cir- trol unit and component. ER, menu
cuit. Check the sensor. 12
60/00 Sensor rpm drum When only one rpm signal Check cable between con- D793/C3 - TRANSM,
(B752) short-circuited that is not the engine rpm trol unit and component. B752 menu 6
to ground. signal is incorrect, the con- Check component.
trol unit calculates the miss-
ing rpm.
If several rpm signals or if
the engine rpm signal are
defective, the control unit
activates Limp-home.
60/01 Sensor rpm drum When only one rpm signal Check cable between con- D793/C3 - TRANSM,
(B752) not connected. that is not the engine rpm trol unit and component. B752 menu 6
signal is incorrect, the con- Check component.
ing rpm.
61/00 Sensor rpm output When only one rpm signal Check cable between con- D793/D3 - TRANSM,
shaft (B758) short- that is not the engine rpm trol unit and component. B758 menu 6
circuited to ground. signal is incorrect, the con- Check component.
ing rpm.

Connec-
tions and Diagnos-
compo- tic menu
nents
Code
61/01 Sensor rpm output When only one rpm signal Check cable between con- D793/D3 - TRANSM,
shaft (B758) not con- that is not the engine rpm trol unit and component. B758 menu 6
nected. signal is incorrect, the con- Check component.
ing rpm.
62/00 Sensor engine rpm When only one rpm signal Check cable between con- D793/F3 - TRANSM,
(B758/766), short- that is not the engine rpm trol unit and component. B758/766 menu 6
circuited to ground. signal is incorrect, the con- Check component.
ing rpm.
62/01 Sensor engine rpm When only one rpm signal Check cable between con- D793/F3 - TRANSM,
(B758/766), not con- that is not the engine rpm trol unit and component. B758/766 menu 6
nected or has open cir- signal is incorrect, the con- Check component.
cuit. trol unit calculates the miss-
ing rpm.
63/00 Sensor rpm turbine When only one rpm signal Check cable between con- D793/R2 - TRANSM,
(B751) short-circuited that is not the engine rpm trol unit and component. B751 menu 6
to ground. signal is incorrect, the con- Check component.
ing rpm.

Connec-
tions and Diagnos-
compo- tic menu
nents
Code
63/01 Sensor rpm turbine When only one rpm signal Check cable between con- D793/R2 - TRANSM,
(B751) not connected. that is not the engine rpm trol unit and component. B751 menu 6
signal is incorrect, the con- Check component.
ing rpm.
70/00 Solenoid valve VFS Transmission in limp-home. Check cabling between con- D793/B1 - TRANSM,
front (Y630), short- trol unit and component. Y630, C1 - menu 8
circuited to each other, Check the solenoid valve. Y630
signal cable short-
circuited to voltage, or
plus-cable short-
circuited to frame
ground.
forward (Y630) open trol unit and component. Y630, C1 - menu 8
circuit or short- Check the solenoid valve. Y630
circuited voltage.
forward (Y630), control trol unit and component. Y630, C1 - menu 9
current higher than Check the solenoid valve. Y630
1400 mA.
forward (Y630), control trol unit and component. Y630, C1 - menu 9
current outside ap- Check the solenoid valve. Y630
proved interval. Incor-
rect impedance.
71/00 Solenoid valve VFS 2/ Transmission in limp-home. Check cabling between con- D793/D1 - TRANSM,
4 (Y6069), short- trol unit and component. Y6069, E1 menu 8
circuited to each other, Check the solenoid valve. - Y6069
signal cable short-
circuited to voltage, or
plus-cable short-
circuited to frame
ground.
4 (Y6069) open circuit trol unit and component. Y6069, E1 menu 8
or short-circuited volt- Check the solenoid valve. - Y6069
age.

Connec-
tions and Diagnos-
compo- tic menu
nents
Code
4 (Y6069), control cur- trol unit and component. Y6069, E1 menu 9
rent higher than 1400 Check the solenoid valve. - Y6069
mA.
4 (Y6069), control cur- trol unit and component. Y6069, E1 menu 9
rent outside approved Check the solenoid valve. - Y6069
interval (incorrect im-
pedance).
72/00 Solenoid valve VFS re- Transmission in limp-home. Check cabling between con- D793/F1 - TRANSM,
verse (Y631), cables trol unit and component. Y631, G1 - menu 8
short-circuited to each Check the solenoid valve. Y631
other, signal cable
short-circuited to volt-
age, or plus-cable
short-circuited to
frame ground.
verse (Y631) open cir- trol unit and component. Y631, G1 - menu 8
cuit or short-circuited Check the solenoid valve. Y631
voltage.
verse (Y631), control trol unit and component. Y631, G1 - menu 9
current higher than Check the solenoid valve. Y631
1400 mA.
verse (Y631), control trol unit and component. Y631, G1 - menu 9
current outside ap- Check the solenoid valve. Y631
proved interval (incor-
rect impedance).
73/00 Solenoid valve VFS 1/ Transmission in limp-home. Check cabling between con- D793/H1 - TRANSM,
3 (Y6067), cables trol unit and component. Y6067, J1 - menu 8
short-circuited to each Check the solenoid valve. Y6067
other, signal cable
age, or plus-cable
short-circuited to
frame ground.
3 (Y6067) open circuit trol unit and component. Y6067, J1 - menu 8
or short-circuited volt- Check the solenoid valve. Y6067
age.

Connec-
tions and Diagnos-
compo- tic menu
nents
Code
3 (Y6067), control cur- trol unit and component. Y6067, J1 - menu 9
rent higher than 1400 Check the solenoid valve. Y6067
mA.
3 (Y6067), control cur- trol unit and component. Y6067, J1 - menu 9
rent outside approved Check the solenoid valve. Y6067
interval (incorrect im-
pedance).
77/02 All gear packs disen- Transmission locked in - - -

gaged. neutral (shutdown).
80/00 Solenoid valve RSP Transmission locked in Check cabling between con- D793/K1 - TRANSM,
Drive (Y6066), cable neutral (shutdown). trol unit and component. Y6066 menu 7
short-circuited to Check the solenoid valve.
frame ground.
80/01 Solenoid valve RSP Transmission locked in Check cabling between con- D793/K1 - TRANSM,
Drive (Y6066), cable is neutral (shutdown). trol unit and component. Y6066 menu 7
not connected or Check the solenoid valve.
age.
81/00 Solenoid valve VFS 2/ Transmission in limp-home. Check cabling between con- D793/E2 - TRANSM,
4 (Y6074), cable short- trol unit and component. Y6074 menu 7
circuited to frame Check the solenoid valve.
ground.
81/01 Solenoid valve VSF 2/ Transmission in limp-home. Check cabling between con- D793/E2 - TRANSM,
4 (Y6074), cable is not trol unit and component. Y6074 menu 7
connected or short- Check the solenoid valve.
circuited to voltage.
82/00 Solenoid valve VFS 1/ Transmission in limp-home. Check cabling between con- D793/F2 - TRANSM,
3 (Y6075), cable short- trol unit and component. Y6075 menu 7
circuited to frame Check the solenoid valve.
ground.
82/01 Solenoid valve VSF 1/ Transmission in limp-home. Check cabling between con- D793/F2 - TRANSM,
3 (Y6075), cable is not trol unit and component. Y6075 menu 7
connected or short- Check the solenoid valve.
circuited to voltage.
83/00 Solenoid valve RSP Transmission locked in Check cabling to solenoid D793/K2 - TRANSM,
Drive (Y6066), cable neutral (shutdown). valve drive Y6066 menu 7
short-circuited to Check solenoid valve drive.
frame ground.

Connec-
tions and Diagnos-
compo- tic menu
nents
Code
83/01 Solenoid valve RSP Transmission locked in Check cabling to solenoid D793/K2 - TRANSM,
Drive (Y6066), cable is neutral (shutdown). valve drive Y6066 menu 7
not connected or Check solenoid valve drive.
age.
90/xx - 99/ System error. Transmission locked in - D793/A:20 -

xx neutral (shutdown).
95/71 Control unit cannot in- - -

terpret input data.
99/90 Incorrect software in - -

control unit transmis-
sion.

96 D Error codes – 8 Control system
8 Control system
mm mm mm mm mm mm
Error codes machine

page
–
Code Description Limitation Action Connections Diagnos- Group

and compo- tic menu
nents
1 Communication error – Use diagnostic menu to D797-1 CAN/POW- 11.6.2 Redun-
with frame control find incorrect segment. ER, menu 1- dant CAN-bus
unit (D797-1). 3

with frame control find incorrect segment. ER, menu 1- dant CAN bus
unit (D797-2) 3

with attachment con- find incorrect segment. ER, menu 1- dant CAN-bus
trol unit (D791-1). 3
8 Communication error – Use diagnostic menu to D795 CAN/POW- 11.6.2 Redun-

with KID control unit find incorrect segment. ER, menu 1- dant CAN-bus
(D795) 3
11 Error in cable, CAN – Use diagnostic menu to Varies depend- CAN/POW- 11.6.2 Redun-
network, segment 1. find incorrect segment. ing on machine ER, menu 1- dant CAN-bus
configuration. 3
configuration. 3
configuration. 3
network, segment 4. find incorrect segment. ing on machine ER, menu 2 dant CAN-bus
configuration. and 3
configuration. 3
19 Accelerator pedal 2 Accelerator Calibrate the gas pedal, D790-1/K6:12 – CALIBRA- 1. Engine
VBFS not calibrated. pedal for rear- see the section 8 Control R690-2 TION: DRIV-
ward operation system, group 8.5.2.3 Cal- ETRAIN,
not working. En- ibrate DRIVE-TRAIN. menu 5 and
gine speed lim- 6
ited to idling
speed.

D Error codes – 8 Control system 97

and compo- tic menu
nents
20 Accelerator pedal not Accelerator Calibrate the gas pedal, D790-1/K6:11 – CALIBRA- 1. Engine
calibrated. pedal for for- see the section 8 Control R690-1 TION: DRIV-
ward operation system, group 8.5.2.3 Cal- ETRAIN,
not working. En- ibrate DRIVE-TRAIN. menu 1 and
gine speed lim- 2
ited to idling
speed.
21 Communication error Gear selection Use diagnostic menu to D790-1/K13:1 – CAN/POW- 11.6.3 CAN-
with transmission not working. check communication. D793/M2 ER, menu 4 bus drivetrain
control unit (D793). Check the wiring between D790-1/K13:2 –
cab control unit (D790-1) D793/L2
and transmission control
unit (D793).
22 Communication error Engine does not Use diagnostic menu to Volvo: D790-1/ CAN/POW- 11.6.3 CAN-
with Control unit en- react to com- check communication. K13:1, K13:2 – ER, menu 4 bus drivetrain
gine (D794). mands from Check the wiring between D794/2, 1
cab. cab control unit (D790-1) Cummins: D790-
and engine control unit 1/K13:1, K13:2 –
(D794) D794/46, 37
23 Setup file cannot be No controls Contact Kalmar Industries D790-1 – 11.5.3.1 Con-
read in cab control working in cab. AB. trol unit cab
unit (D790-1).
24 Electric power feed Cab fan not Check fuse F58-5/3. D790-1/K2:8 – – 9.4.3 Cab fan
to cab fan less than working. 58-5/3:2
18 V.
25 Interference during Error code Switch the ignition off and D794 ENGINE, 11.5.3.10 Con-
software download. stored in engine on. menu 8 trol unit engine
26
Buffer for error codes control unit Repeat software down-
27 from engine control (D794). load.
unit (D794), active
28
error code when
29 downloading.
30
31 Incorrect power sup- Control in cab Check fuse F58-5/1. D790-1/K1:2, CAN/POW- 11.5.1.3 Igni-
ply to cab control unit not working. Check cabling between K1:3, K1:4 – ER, menu 7 tion voltage
(D790-1). Voltage the control unit and the F58-5/1:1, 1:2 (15)
under 18 V or over 32 component with diagnos-
V. tic menu.


and compo- tic menu
nents
32 Incorrect 5 V refer- Analogue con- Check the wiring between D790-1/K4:5, K CAN/POW- 11.5.3.1 Con-
ence voltage to ana- trols in the cab the control unit and com- 5:11, K5:13, ER, menu 7 trol unit cab
logue cab controls. not working ponent with the diagnostic K7:2, K 9:7
Voltage under 4.9 V (mini-wheel/joy- menu.
or over 5.1 V. stick, control le- Check component.
ver and controls
for air condition-
ing).
33 No feedback signal The emergency Check fuse F58-3/8. D790-1/K11:13 – CAN/POW- 11.5.1.4 Emer-
for emergency stop stop switch can- Check cabling between K3009-1/87 ER, menu 5 gency stop
switch voltage from not be disen- the control unit and the switch voltage
emergency stop gaged. All component with diagnos- (15E)
switch voltage relay hydraulic func- tic menu.
(K3009-1). tions are
blocked.
34 Faulty signal from Parking brake Check cabling between D791-1/K8:5 – HYD, menu 4.5 Parking
parking brake switch cannot be re- the control unit and the S107/7 5 brake
(S107); indicates released. component with diagnos- D791-1/K8:13 –
leased and applied at tic menu. S107/1
same time or nothing Check the switch.
at all.
35 Interference during Error code Switch the ignition off and D793 TRANSM, 11.5.3.9 Con-
software download. stored in trans- on. menu 13 trol unit trans-
36
Buffer for error codes mission control Repeat software down- mission
37 from transmission unit (D793). load.
control unit (D793),
38
active error code
39 when downloading.
40
41 Transistor has been Windshield wip- Check cabling between D790-1/K2:4 – CAB, menu 9.5.7 Wiper
triggered due to short er rear not the control unit and the M650-2/53 3 motor rear
circuit or open circuit working. component with diagnos-
in circuit for rear wip- tic menu.
er motor (M650-2). Check the motor.
42 Transistor has been Rotating bea- Check cabling between D790-1/K2:5 – LIGHTS, 9.6.8 Rotating
triggered due to short con not work- the control unit and the H428 menu 6 beacon
circuit or open circuit ing. component with diagnos-
in circuit for rotating tic menu.
beacon (H428). Check the component.
43 Transistor has been Left cab revers- Check bulb. D790-1/K2:6 – LIGHTS, 9.6.5 Back-up
triggered due to short ing light not Check cabling between E405L menu 8 light
circuit or open circuit working. the control unit and the
in circuit for left re- component with diagnos-
versing light (E405L). tic menu.


and compo- tic menu
nents
44 Transistor has been Right cab re- Check bulb. D790-1/K2:7 – LIGHTS, 9.6.5 Back-up
triggered due to short versing light not Check cabling between E405R menu 8 light
circuit or open circuit working. the control unit and the
in circuit for right re- component with diagnos-
versing light tic menu.
(E405R).
45 Transistor has been Windshield wip- Check cabling between D790-1/K2:1 – CAB, menu 9.5.5 Wiper
triggered due to short er front not the control unit and the M650-1/53 2 motor front
in circuit for front wip- tic menu.
er motor (M650-1). Check the component.
46 Transistor has been Cab fan not Check cabling between D790-1/K2:2 – CLIMATE, 9.4.3 Cab fan
triggered due to short working. the control unit and the M657/2 menu 6
circuit or open circuit component with diagnos-
in circuit for fan mo- tic menu.
tor (M657). Check the motor.
47 Transistor has been Recirculation Check cabling between D790-1/K2:3 – CLIMATE, 9.4.2 Fresh air
triggered due to short damper to venti- the control unit and the M612/3 menu 6 filter and recir-
circuit or open circuit lation not work- component with diagnos- culation damp-
in circuit for recircula- ing. tic menu. er
tion actuating motor Check the motor.
(M612).
48 Transistor has been Heat in cab can- Check cabling between D790-1/K4:1 – CLIMATE, 9.4.5 Water
triggered due to short not be adjusted. the control unit and the Y673/5 menu 7 valve
in circuit for water tic menu.
valve (Y673). Check the motor.
49 Transistor has been Heat in cab can- Check cabling between D790-1/K4:2 – CLIMATE, 9.4.5 Water
triggered due to short not be adjusted. the control unit and the Y673/6 menu 7 valve
in circuit for water tic menu.
valve (Y673). Check the motor.
50 Transistor has been Air distribution Check cabling between D790-1/K4:3 – CLIMATE, 9.4.14 Air dis-
triggered due to short in cab cannot the control unit and the Y672/5 menu 8 tributor
circuit or open circuit be adjusted. component with diagnos-
in circuit for actuating tic menu.
motor (Y672). Check the motor.
51 Transistor has been Air distribution Check cabling between D790-1/K4:4 – CLIMATE, 9.4.14 Air dis-
triggered due to short in cab cannot the control unit and the Y672/6 menu 8 tributor
circuit or open circuit be adjusted. component with diagnos-
in circuit for actuating tic menu.
motor (Y672). Check the motor.


and compo- tic menu
nents
52 Transistor has been Bypass of exter- Check component. D790-1/K5:3 – - -
triggered due to short nal top lift at- Check the wiring.
circuit or open circuit tachment not
in circuit for bypass working.
of external top lift at-
tachment.
53 Transistor has been Windshield Check cabling between D790-1/K5:4 – CAB, menu 9.5.4 Washer
triggered due to short washer rear and the control unit and the M651-2 1 motor and res-
circuit or open circuit roof not work- component with diagnos- ervoir
in circuit for roof and ing. tic menu.
rear washer motor Check the motor.
(M651-2).
54 Transistor has been Flashing hazard Check cabling between D790-1/K5:5 – LIGHTS, 9.6.7 Flashing
triggered due to short lights not work- the control unit and the S109/ menu 7 hazard lights
circuit or open circuit ing. component with diagnos-
in circuit for flashing tic menu.
hazard light switch Check the switch.
(S109).
55 Transistor has been Reduced or no Check bulbs for back- D7901/K6:1, K LIGHTS, 9.1 Controls
triggered due to short background ground lighting, change if 8:15, K 9:2, all in- menu 14 and instru-
circuit or open circuit lighting in needed. puts of type A ments
in circuit for back- switches and in- Check cable harness to Digital in
ground lighting in struments background lighting.
switches and instru-
ments.
56 Transistor has been Work lights 20’ Check cabling between D790-1/ K7:8 – LIGHTS, 9.6.10 Work-
triggered due to short not working. the control unit and the R3017-2/86 menu 12 ing lights, cab
in circuit for relay for tic menu.
20’ working lights. Check the component.
57 Transistor has been Indicator light Check cabling between D790-1/ K7:9 – - 7.1.1 Control
triggered due to short for levelling lock the control unit and the S815/7 levers/Joystick
circuit or open circuit in joystick not component with diagnos-
in circuit for indicator working. tic menu.
light for levelling lock Check the component.
in joystick (S815).
58 Transistor has been Twistlock on ex- Check cabling between D790-1/ K7:10 – EXT-AT- 7.9.2 Twist-
triggered due to short ternal top lift at- the control unit and the K3005/86 TACH, locks
circuit or open circuit tachment does component with diagnos- menu 6
in circuit for relay for not work. tic menu.
twistlock on external Check the component.
top lift attachment
(K3005).


and compo- tic menu
nents
59 Transistor has been Spreading on Check cabling between D790-1/ K7:11 – EXT-AT- 7.10.5.1
triggered due to short external top lift the control unit and the K3006/86 TACH, Spreading
circuit or open circuit attachment component with diagnos- menu 6
in circuit for relay for does not work. tic menu.
spreading on exter- Check the component.
nal top lift attachment
(K3006).
60 Transistor has been Seat heating Check cabling between D790-1/ K10:7 – CAB, menu 9.3.3 Heating
triggered due to short does not work. the control unit and the K383/86 8 coils
heating element in Check the component.
operator’s seat
(K383).
61 Transistor has been Work lights 40’ Check cabling between D790-1/ K10:8 – LIGHTS, 9.6.10 Work-
triggered due to short not working. the control unit and the K3017-1/86 menu 12 ing lights, cab
40’ working lights Check the component.
(K3017-1).
63 Transistor has been No ignition volt- Check cabling between D790-1/K10:10 – CAN/POW- 11.5.1.3 Igni-
triggered due to short age to the ma- the control unit and the K315-1/86 ER, menu 5 tion voltage
circuit or open circuit chine’s Control component with diagnos- (15)
in circuit for relay for units. tic menu.
ignition voltage Check the component.
(K315-1).
64 Transistor has been No emergency Check cabling between D790-1/K10:11 – CAN/POW- 11.5.1.4 Emer-
triggered due to short stop switch volt- the control unit and the K3009-1/86 ER, menu 6 gency stop
circuit or open circuit age to the ma- component with diagnos- switch voltage
in circuit for relay for chine’s control tic menu.
emergency stop units. Check the component.
switch voltage
(K3009-1).
65 Transistor has been No emergency Check cabling between D790-1/K10:12 – CAN/POW- 11.5.1.4 Emer-
triggered due to short stop switch volt- the control unit and the K3009-2/86 ER, menu 6 gency stop
circuit or open circuit age to the ma- component with diagnos- switch voltage
in circuit for relay for chine’s control tic menu.
emergency stop units. Check the component.
switch voltage
(K3009-2).


and compo- tic menu
nents
66 Transistor has been Windshield Check cabling between D790-1/K10:13 – CAB, menu 9.5.4 Washer
triggered due to short washer not the control unit and the M651-1, M651-2 1 motor and res-
circuit or open circuit working. component with diagnos- ervoir
in circuit for wind- tic menu.
screen washer motor Check the component.
(M651-1, M651-2).
67 Transistor has been Wiper roof not Check cabling between D790-1/K10:14 – CAB, menu 9.5.6 Wiper
triggered due to short working. the control unit and the M650-3 4 motor roof
in circuit for roof wip- tic menu.
er motor (M650-3). Check the motor.
68 Transistor has been Pause heater Check cabling between D790-1/K10:15 – - 9.4 Heating,
triggered due to short not working. the control unit and the M667 ventilation and
circuit or open circuit component with diagnos- air conditioning
in circuit for pause tic menu.
heater circulation Check the motor.
pump (M667).
69 Transistor has been No voltage feed Check cabling between D790-1/K10:16 – - 11.5.1.3 Igni-
triggered due to short to engine and the control unit and the K315-2/86 tion voltage
circuit or open circuit transmission. component with diagnos- (15)
drivetrain ignition Check the component.
voltage (K315-2).
71 Transistor has been Interior lighting Check bulb. D790-1/K11:6 – LIGHTS, 9.6.11 Interior
triggered due to short in cab not work- Check cabling between E434-1 menu 9 lighting cab
circuit or open circuit ing. the control unit and the
in circuit for cab inte- component with diagnos-
rior lighting (E434-1). tic menu.
75 Relay ignition volt- The cab control Check cabling between - CAN/POW- 11.5.1.3 Igni-
age (K315-1) has unit (D790-1) the control unit and the ER, menu 5 tion voltage
jammed in position still has a power component with diagnos-
on. supply and is tic menu.
thereby active. Check the component.
80 No signal from Pres- Air conditioning Check drive belt for air D797-1/K1:40 – CLIMATE, 9.4.10 Pres-
sure switch air condi- not working. conditioning compressor. S246 menu 3 sure switch
tioning (S246), Check that compressor for
despite the AC com- air conditioning is activat-
pressor being acti- ed.
vated.
the control unit and the
component with diagnos-
tic menu.


and compo- tic menu
nents
81 Faulty signal from Air distribution Check cabling between D790-1/K4:7 – CLIMATE, 9.4.6 Fresh air
actuating motor cannot be the control unit and the Y672/9 menu 4 and recircula-
(Y672). Signal volt- changed. component with diagnos- tion damper
age under 0.2 V or tic menu.
over 4.8 V. Check the motor.
85 Faulty signal from Accelerator Check cabling between D790-1/K6:11 – ENGINE, 1 Engine
accelerator pedal pedal for for- the control unit and the B690-1/2 menu 1
(B690-1). Signal volt- ward operation component with diagnos-
age under 0.2 V or not working. En- tic menu.
over 4.8 V. gine speed lim- Check the component.
ited to idling
speed.
86 Faulty signal from Accelerator Check the wiring between D790-1/K6:12 – VBFS, menu 1 Engine
auxiliary accelerator pedal for rear- the control unit and com- B690-2/2 4
pedal (B690-2). Sig- ward operation ponent with the diagnostic
nal voltage under 0.2 not working. En- menu.
V or over 4.8 V. gine speed lim- Check component.
ited to idling
speed.
87 Faulty signal from lift- Lifting/lowering Check cabling between D790-1/K7:3 – ELSERV, 7.1.1 Control
ing/lower control le- not working. the control unit and the R8071/3 menu 1 (P1) lever
ver (R8071). Signal component with diagnos-
voltage under 0.2 V tic menu.
or over 4.8 V. Check the lever.
88 Faulty signal from tilt Tilt not working. Check cabling between D790-1/K7:4 – ELSERV, 7.1.1 Control
control lever the control unit and the R8072/3 menu 1 (P2) lever
(R8072). Signal volt- component with diagnos-
age under 0.2 V or tic menu.
over 4.8 V. Check the lever.
89 Faulty signal from Side shift not Check cabling between D790-1/K7:5 – ELSERV, 7.1.1 Control
side shift control le- working. the control unit and the R8073/3 menu 1 (P3) lever
ver (R8073). Signal component with diagnos-
or over 4.8 V. Check the lever.


and compo- tic menu
nents
90 DCF280-500/ Spreading not Check cabling between D790-1/K7:6 – ELSERV, 7.1.1 Control
DCF90-100 working. the control unit and the R8074/3 menu 2 (P4) lever
Faulty signal from component with diagnos-
spreading control le- tic menu.
ver (R8074). Signal Check the lever.
voltage under 0.2 V
or over 4.8 V.
DCF360-450CSG Extension left

Faulty signal from not working.
control lever for ex-
tension left (R8074).
Signal voltage under
0.2 V or over 4.8 V.
91 DCF280-500/ Extra load han- Check the wiring between D790-1/K7:7 – ELSERV, 7.1.1 Control
DCF90-100 dling function the control unit and com- R8075-1/3 menu 2 (P5) lever
Faulty signal from not working. ponent with the diagnostic
auxiliary function menu.
control lever (R8075- Check component.
1). Signal voltage un-
der 0.2 V or over 4.8
V.
DCF360-450CSG Levelling not

Faulty signal from working.
levelling control lever
(R8075-1). Signal
voltage under 0.2 V
or over 4.8 V.
92 Faulty signal from Joystick steer- Check cabling between D790-1/K9:8 – EL-STEER- 5.1.2 Mini-
steering lever (R825- ing or mini- the control unit and the R825-1/H1 ING, menu 1 wheel
1) or mini-wheel wheel not work- component with diagnos- 5.1.3 Joystick
(R825-1). Signal volt- ing. tic menu.
age under 0.2 V or Check the switch.
over 4.8 V.
93 Faulty signal from Joystick steer- Check cabling between D790-1/K9:9 – EL-STEER- 5.1.2 Mini-
mini-wheel (R825-2). ing or mini- the control unit and the R825-2/H2 ING, menu 1 wheel
Signal voltage under wheel not work- component with diagnos-
0.2 V or over 4.8 V. ing. tic menu.
Check the switch.
94 Faulty signal from Cab heat can- Check cabling between D790-1/K10:4 – CLIMATE, 9.4.5 Water
cab heater water not be adjusted. the control unit and the Y673/9 menu 4 valve
valve (Y673). Signal component with diagnos-
or over 4.8 V. Check the motor.


and compo- tic menu
nents
95 DCF280-500/ Extra load han- Check cabling between D790-1/K9:9 – ELSERV, 7.1.1 Control
DCF90-100 dling function the control unit and the R8075-2/3 menu 2 (P7) lever
Faulty signal from not working. component with diagnos-
auxiliary function tic menu.
control lever (R8075- Check the lever.
V.
DCF360-450CSG Extension right

Faulty signal from not working.
control lever for ex-
tension right (R8075-
V.
96 Faulty signal from Air conditioning Check cabling between D790-1/K4:8 – CLIMATE, 9.4.17 Sensor
cab temperature not working. the control unit and the B775-1/2 menu 1 cab tempera-
sensor (B775-1) component with diagnos- ture
Sensor indicates tic menu.
temperature under Check the sensor.
-43 °C or over 105
°C.
outdoor temperature not working. the control unit and the B774/2 menu 2 outdoor tem-
sensor (B774). Tem- component with diagnos- perature
perature signal over tic menu.
105 °C. Check the sensor.
outlet fan tempera- not working. the control unit and the B775-2/2 menu 2 temperature
ture sensor (B775-2) component with diagnos- outlet fan
temperature under - Check the sensor.
43 °C or over 105 °C.
99 Faulty signal from re- Air conditioning Check cabling between D790-1/K4:11 – CLIMATE, 9.4.12 Sensor
frigerant temperature not working. the control unit and the B775-3/2 menu 2 temperature
sensor (B775-3) component with diagnos- refrigerant
temperature under - Check the sensor.
43 °C or over 105 °C.
101 Redundant voltage – Check cabling between D797-1/K2:7 CAN/POW- 11.5.1.2 Re-
feed left to frame the control unit and the ER, menu dundant volt-
control unit (D797-1) component with diagnos- 10 age feed of
does not reach desti- tic menu. control units
nation. Check the control unit.


and compo- tic menu
nents
feed right to frame the control unit and the ER, menu dundant volt-
does not reach desti- tic menu. control units
103 Incorrect power sup- No electric pow- Check fuse F58-2/1, D797-1/K2:1, CAN/POW- 11.5.1.3 Igni-
ply to frame control er feed to com- change if needed. K2:9, K2:10 – ER, menu tion voltage
unit (D797-1). Volt- ponents. Check cabling between F58-2/1:1, 1:2 10 (15)
age under 18 V or the control unit and the
over 32 V. component with diagnos-
tic menu.
104 Incorrect emergency Functions nor- Check fuse F58-2:1 and D797-1/K2:11 – CAN/POW- 11.5.1.4 Emer-
stop switch voltage mally supplied replace if necessary. F58-2/1:1 ER, menu gency stop
to frame control unit emergency stop Check the wiring between 10 switch voltage
(D797-1). switch voltage the control unit and com-
have no feed. ponent with the diagnostic
All hydraulic menu.
functions
Check component.
blocked.
105 Incorrect 5 V refer- Incorrect func- Check cabling between D797-1/K1:8 – CAN/POW- 8.2.1 Overload
ence voltage to pres- tion, lift and tilt the control unit and the B768-1/1, B768- ER, menu protection
sure sensor. Voltage sensor. component with diagnos- 2/1 11
under 4.9 V or over tic menu.
5.1 V. Check the sensor.
106 Transistor has been Cooling fan hy- Check cabling between D797-1/K1:14 – HYD, menu 10.6.3 Cooling
triggered due to short draulic oil not the control unit and the M668/1 1 fan
in circuit for hydraulic tic menu.
oil cooling fan Check the motor.
(M668).
107 Transistor has been Mast work lights Check bulb. D797-1/K1:1 – LIGHTS, 9.6.9 Working
triggered due to short not working. Check the lamp holder. E404L-1, menu 10 lights mast
circuit or open circuit E404R-1
in circuit for mast
work lights (E404R-
1, E404L-1).
tic menu.
108 Transistor has been High beam not Check bulb. D797-1/K1:15 – LIGHTS, 9.6.1 Head-
triggered due to short working. Check the lamp holder. E402L-1, menu 3 lights
circuit or open circuit E402R-1
in circuit for high
beam (E402R-1,
E402L-1).
tic menu.


and compo- tic menu
nents
109 Transistor has been Low beams not Check bulb. D797-1/K1:28 – LIGHTS, 9.6.1 Head-
triggered due to short working. Check the lamp holder. E400L, E400R menu 3 lights
circuit or open circuit
in circuit for low
beam (E400L,
E400R).
tic menu.
111 Transistor has been Running lights Check bulb. D797-1/K1:2 – LIGHTS, 9.6.2 Running
triggered due to short not working. Check the lamp holder. H416-1, H416-2, menu 2 lights
circuit or open circuit H417-1, H417-2
in circuit for running Check cabling between
lights (H416-1,
H416-2, H417-1,
tic menu.
H417-2).
112 Transistor has been Cooling fan Check cabling between D797-1/K1:3 – HYD, menu 4.8.9 Cooling
triggered due to short brake oil not the control unit and the M674/1 2 fan
in circuit for brake oil tic menu.
cooling fan (M674). Check the motor.
113 Electric servo Lifting/lowering Check cabling between D797-1/K1:4 – ELSERV, DCF280-500:
Transistor has been not working. the control unit and the Y6004/1, Y6005/ menu 3 and 7.2.6 Control
triggered due to short component with diagnos- 1 4 valve, load
circuit or open circuit tic menu. handling
in circuit for solenoid Check the solenoid DCF360-
valve, lift mast valves. 450CSG: 7.2.5
(Y6005) and sole- Control valve,
noid valve, lower lift and tilt
mast (Y6004).
114 Electric servo Tilt not working. Check cabling between D797-1/K1:5 – ELSERV, DCF280-500:
Transistor has been the control unit and the Y6010/1, Y6011/ menu 5 and 7.7.5 Control
triggered due to short component with diagnos- 1 6 valve, load
circuit or open circuit tic menu. handling
in circuit for solenoid Check the solenoid valve. DCF360-
valve, tilt in (Y6011) 450CSG: 7.7.5
and solenoid valve, Control valve,
tilt out (Y6010). lift and tilt
115 Transistor has been Left direction in- Check bulb. D797-1/K1:30 – LIGHTS, 9.6.6 Direction
triggered due to short dicator not Check the lamp holder. H422/1, H426/1 menu 4 indicators
circuit or open circuit working.
in circuit for left direc- Check cabling between
tion indicator (H422, the control unit and the
H426). component with diagnos-
tic menu.


and compo- tic menu
nents
116 Transistor has been Right direction Check bulb. D797-1/K1:31 – LIGHTS, 9.6.6 Direction
triggered due to short indicator not Check the lamp holder. H423/1, H427/1 menu 4 indicators
in circuit for right di- Check cabling between
rection indicator the control unit and the
(H423, H427). component with diagnos-
tic menu.
117 Transistor has been Starter motor Check cabling between D797-1/K1:32 – ENGINE, 1.11 Start and
triggered due to short not working. the control unit and the K315/85 menu 5 stop
in circuit for start re- tic menu.
lay (K315) for starter Check the component.
motor.
118 Transistor has been Tail lights not Check bulb. D797-1/K1:33 – LIGHTS, 9.6.3 Rear
triggered due to short working. Check the lamp holder. H412L/1, menu 2 lights
circuit or open circuit H412R/1
in circuit for tail light
(H412L, H412R).
tic menu.
119 Transistor has been Brake light left Check bulb. D797-1/K1:7 – LIGHTS, 9.6.4 Brake
triggered due to short not working. Check the lamp holder. H411L/1 menu 8 lights
in circuit for left brake
light (H411L).
tic menu.
120 Transistor has been Brake light right Check bulb. D797-1/K1:9 – LIGHTS, 9.6.4 Brake
triggered due to short not working. Check the lamp holder. H411R/1 menu 8 lights
in circuit for right
brake light (H411R).
tic menu.
121 Transistor has been Back-up alarm Check cabling between D797-1/K1:10 – LIGHTS, 9.7.5 Back-up
triggered due to short not working. the control unit and the H965/1 menu 8 alarm
in circuit for reversing tic menu.
warning device Check the component.
(H965).


and compo- tic menu
nents
122 Transistor has been Air conditioning Check cabling between D797-1/K1:25 – CLIMATE, 9.4.7 Com-
triggered due to short not working. the control unit and the M645/1 menu 6 pressor
123 D797-1/K1:29 –
in circuit for electro- tic menu.
M645/1
magnetic clutch of Check the component.
AC compressor
(M645).
NOTE! Error code
122 and 123 apply to
the same user.
124 Transistor has been Disconnection Check cabling between D797-1/K1:34 – HYD, menu 10.4.3 Vane
triggered due to short of pump 2 not the control unit and the Y6062/1 6 pump with fixed
circuit or open circuit working. component with diagnos- displacement
in circuit for solenoid tic menu.
valve, hydraulic Check the solenoid valve.
pump disengage-
ment (Y6062).
125 Transistor has been Regeneration Check cabling between D797-1/K1:11 – ELSERV, 7.2.6 Valve
triggered due to short not working. the control unit and the Y6051/1 menu 15 block lift cylin-
circuit or open circuit component with diagnos- der
valve regeneration, Check component.
lift, right (Y6051).
126 Transistor has been Regeneration Check cabling between D797-1/K1:12 – ELSERV, 7.2.6 Valve
triggered due to short not working. the control unit and the Y6052/1 menu 15 block lift cylin-
circuit or open circuit component with diagnos- der
valve regeneration, Check component.
lift, left (Y6052).
132 Vehicle Data file Some functions - - - -

missing. in machine not
working.
133 Faulty signal from Scales, regen- Check the sensor. D797-1/K1:21 – HYD, menu 7.2.8 Sensor
hydraulic pressure eration and Check cabling between B768-1/3 3 hydraulic pres-
sensor for lift cylinder slack chain log- the control unit and the OLS, menu sure lift cylinder
(B768-1). ic, not working. component with diagnos- 1
Overload sys- tic menu.
tem not work-
ing. Error code
150 activated.
134 Faulty signal from Overload sys- Check the sensor. D797-1/K1:22 – HYD, menu 7.7.8 Hydraulic
hydraulic pressure tem not work- Check cabling between B768-2/3 3 pressure sen-
sensor for tilt cylinder ing. Error code the control unit and the OLS, menu sor, tilt cylinder
(B768-2). 150 activated. component with diagnos- 1
tic menu.


and compo- tic menu
nents
135 No feedback signal - Check that cooling fan is D797-1/K2:6 – HYD, menu 4.8.9 Cooling
from brake oil cooling working. M674/2 2 fan
fan (M674). Check cabling between
tic menu.
137 Electric servo Lift mast not Check cabling between D797-1/K1:16 – ELSERV, DCF280-500:
Faulty signal from working. the control unit and the Y6005/2 menu 3 7.7.5 Control
solenoid valve for lift component with diagnos- valve, load
mast (Y6005). Re- tic menu. handling
turn current does not Check the solenoid valve. DCF360-
match control cur- 450CSG: 7.7.5
rent. Control valve,
lift and tilt
138 Electric servo Lower mast not Check cabling between D797-1/K1:17 – ELSERV, DCF280-500:
solenoid valve for component with diagnos- valve, load
lower mast (Y6004). tic menu. handling
Return current does Check the solenoid valve. DCF360-
not match control 450CSG: 7.7.5
current. Control valve,
lift and tilt
139 Electric servo Tilt in not work- Check cabling between D797-1/K1:18 – ELSERV, DCF280-500:
Faulty signal from ing. the control unit and the Y6011/2 menu 5 7.7.5 Control
solenoid valve for tilt component with diagnos- valve, load
in (Y6011). Return tic menu. handling
current does not Check the solenoid valve. DCF360-
lift and tilt
140 Electric servo Tilt out not Check cabling between D797-1/K1:19 – ELSERV, DCF280-500:
solenoid valve for tilt component with diagnos- valve, load
out (Y6010). Return tic menu. handling
current does not Check the solenoid valve. DCF360-
lift and tilt
141 Transistor has been Parking brake Check cabling between D797-1/K1:34 – HYD, menu 4.5.3 Solenoid
triggered due to short cannot be re- the control unit and the Y642/1 5 valve parking
circuit or open circuit leased. component with diagnos- brake
in circuit for parking tic menu.
brake solenoid valve Check the solenoid valve.
(Y642).


and compo- tic menu
nents
142 DCF280-500 Tilt not working. Check cabling between D797-1/K1:35 – OLS, menu 7.10.5 Sepa-
Transistor has been the control unit and the Y6012/1 7 rate top lift at-
triggered due to short component with diagnos- tachment
circuit or open circuit tic menu.
in circuit for solenoid Check the solenoid valve.
valve, stop tilt
(Y6012).
DCF360-450CSG Disconnection Check cabling between D797-1/K1:35 – HYD, menu 10.4.2 Axial
Transistor has been of attachment the control unit and the Y6062/1 6 piston pump
triggered due to short pump not work- component with diagnos- with variable
circuit or open circuit ing. tic menu. displacement
valve, hydraulic
pump disengage-
ment (Y6062).
DCF90-100 Quick-lift pump Check cabling between D797-1/K1:35 – HYD, menu 10.4.2 Axial
Transistor has been engagement the control unit and the Y6062/1 6 piston pump
triggered due to short not working. component with diagnos- with variable
circuit or open circuit tic menu. displacement
valve, hydraulic
pump disengage-
ment (Y6062).
143 Transistor has been Spreading and Check cabling between D797-1/K1:36 – EXT-AT- 7.10.5 Sepa-
triggered due to short twistlocks on the control unit and the Y6039/6018/1 TACH, rate top lift at-
circuit or open circuit top lift attach- component with diagnos- menu 5 tachment
in circuit for solenoid ment not work- tic menu.
valve, lock twist- ing. Check the solenoid valve.
locks/spreading out
(Y6039/6018).
144 Transistor has been Spreading and Check cabling between D797-1/K1:37 – EXT-AT- 7.10.5 Sepa-
triggered due to short twistlocks on the control unit and the Y6040/6019/1 TACH, rate top lift at-
circuit or open circuit top lift attach- component with diagnos- menu 5 tachment
in circuit for solenoid ment not work- tic menu.
valve, open twist- ing. Check the solenoid valve.
locks/spreading in
(Y6040/6019).
145 High brake oil tem- Reduced brak- Check that cooling fan is D797-1/K2:6 – HYD, menu 4.8.10 Sensor
perature. ing capacity. If working. B772/1 2 brake oil tem-
the temperature Check that cooler isn’t perature
continues to clogged.
rise, speed is
Check the brake oil level.
limited to 5 km/
h. Check the sensor.


and compo- tic menu
nents
146 Faulty signal from Speed limited to Check the sensor. D797-1/K2:6 – HYD, menu 4.8.10 Sensor
brake oil temperature 5 km/h. Check cabling between B772/1 2 brake oil tem-
sensor (B772). Sig- the control unit and the perature
nal voltage under 0.2 component with diagnos-
V or over 4.8 V. tic menu.
147 High hydraulic oil No limitation. Check that cooling fan is D797-1/K2:13 – HYD, menu 10.6.4 Sensor
temperature. working. B776/1 1 hydraulic oil
Check that cooler isn’t temperature
clogged.
Check the sensor.
148 Faulty signal from Incorrect tem- Check the sensor. D797-1/K2:13 – HYD, menu 10.6.4 Sensor
hydraulic oil temper- perature dis- Check cabling between B776/1 1 hydraulic oil
ature sensor (B776). play. the control unit and the temperature
tic menu.
149 Faulty signal from Incorrect dis- Check the sensor. D797-1/K2:15 – CAB, menu 1.2.2 Sensor
fuel level sensor play of fuel Check cabling between B757/1 7 fuel level
(B757). Resistance amount (empty the control unit and the
over 180 Ω. or full). component with diagnos-
tic menu.
150 Defective overload Overload sys- Check if there are error – OLS, menu 8.2.1 Overload
protection. tem not work- codes for sensors in the 1–7 protection
This error code can- ing. All lift overload system.
not be removed with functions oper-
Reset. ate at reduced
speed.
control unit option component with diagnos- 13 age feed of
(D797-2) does not tic menu. Control units
reach destination. Check the control unit.
control unit option component with diagnos- 13 age feed of
(D797-2) does not tic menu. Control units
reach destination. Check the control unit.
153 Incorrect power sup- No electric pow- Check fuse F58-2/3, D797-2/K2:1/9/ CAN/POW- 11.5.1.3 Igni-
ply to frame control er feed to com- change if needed. 10 ER, menu tion voltage
unit option (D797-2). ponents. Check cabling between D797-2/K2:1, 13 (15)
Voltage under 18 V the control unit and the K2:9, K2:10 –
or over 32 V. component with diagnos- F58-2/3:1, 3:2
tic menu.


and compo- tic menu
nents
154 Incorrect control Functions nor- Check fuse F58-3/5; re- D797-F/K2:11 – CAN/POW- 11.5.1.4 Emer-
switch voltage to mally supplied place if needed. F58-3/5:1 ER, menu gency stop
frame option control emergency stop Check cabling between 13 switch voltage
unit (D797-2). switch voltage the control unit and the
have no feed. component with diagnos-
All hydraulic tic menu.
functions
blocked.
155 Incorrect 5 V refer- – Check cabling between D797-2/K1:8 CAN/POW- 11.5.1 Power
ence voltage to pres- the control unit and the ER, menu supply
sure sensor. Voltage component with diagnos- 14
157 Transistor has been Rear high beam Check bulb. D797-2/K1:1 – VBFS, menu 9.6.1 Head-
triggered due to short not working. Check the lamp holder. E402R-2/1, 6 lights
circuit or open circuit E402L-2/1
in circuit for rear high
beam (E402R-2,
E402L-2).
tic menu.
158 Transistor has been Rear low beam Check bulb. D797-2/K1:15 – VBFS, menu 9.6.1 Head-
triggered due to short not working. Check the lamp holder. E401R/1, E401L/ 6 lights
circuit or open circuit 1
in circuit for rear low
beam (E401R,
E401L).
tic menu.
160 Transistor has been Auxiliary work Check the lights. Check D797-2/K1:42 – LIGHTS, 9.6.9 Working
triggered due to short lights, frame the wiring between the E404R-2/1, menu 11 lights mast
circuit or open circuit front, not work- control unit and compo- E404L-2/1 9.6.10 Work-
in circuit for auxiliary ing. nent with the diagnostic ing lights, cab
work lights (E404R- menu.
2, E404L-2). 9.6.12 Work
Check component. lights, attach-
ment
161 Transistor has been Joystick steer- Check cabling between D797-2/K1:2 – EL-STEER- 5.2.10 Control
triggered due to short ing or mini- the control unit and the Y636-3/1 ING, menu 5 valve joystick
circuit or open circuit wheel not work- component with diagnos- steering/mini-
in circuit for solenoid ing. tic menu. wheel
valve, steering right Check the solenoid valve.
(Y636-3).


and compo- tic menu
nents
162 Transistor has been Joystick steer- Check cabling between D797-2/K1:3 – EL-STEER- 5.2.10 Control
triggered due to short ing or mini- the control unit and the Y636-4 /1 ING, menu 4 valve joystick
circuit or open circuit wheel not work- component with diagnos- steering/mini-
in circuit for solenoid ing. tic menu. wheel
valve, steering right Check the solenoid valve.
(Y636-4).
163 Transistor has been Lift carriage not Check cabling between D797-2/K1:4 – ELSERV, 7.2.6 Control
triggered due to short working. the control unit and the Y6022/1 menu 11 valve load han-
circuit or open circuit component with diagnos- dling
valve, lift carriage Check the solenoid valve.
(Y6022).
164 Transistor has been Lower carriage Check cabling between D797-2/K1:5 – ELSERV, 7.2.6 Control
triggered due to short not working. the control unit and the Y6023/1 menu 12 valve load han-
valve, lower carriage Check the solenoid valve.
(Y6023).
165 Transistor has been Side shift right Check cabling between D797-2/K1:30 – ELSERV, 7.4.5 Control
valve, side shift right Check the solenoid valve.
(Y6021).
166 Transistor has been Side shift left Check cabling between D797-2/K1:31 – ELSERV, 7.4.5 Control
valve, side shift left Check the solenoid valve.
(Y6020).
167 Transistor has been Spreading in Check cabling between D797-2/K1:32 – ELSERV, 7.5.5 Control
valve, spreading in Check the solenoid valve.
(Y6019).
168 Transistor has been Spreading out Check cabling between D797-2/K1:33 – ELSERV, 7.5.5 Control
valve, spreading out Check the solenoid valve.
(Y6018).


and compo- tic menu
nents
169 Reversible opera- Operator’s seat Check cabling between D797-2/K1:7 – CAN/POW- 9.3.9.2 Sensor,
tor's seat position indica- the control unit and the S720-F/1, S720- ER, menu reversible op-
Transistor has been tor not working. component with diagnos- R/1 14 erator’s seat
triggered due to short tic menu.
circuit or open circuit Check the sensor.
in circuit for reversi-
ble operator’s seat
sensor (S720-F,
S720-R).
Tiltable cab Cab position in- Check cabling between D797-2/K1:7 – CAN/POW- 9.10.4.7 Sen-
Transistor has been dicator not the control unit and the B769-1/A, B769- ER, menu sor, cab up/cab
triggered due to short working. component with diagnos- 2/A 14 down
in circuit for sensor Check the sensor.
for cab tilt (B769-1,
B769-2).
170 Transistor has been Change of Check cabling between D797-2/K1:9 – VBFS, menu 5.2.15 Direc-
triggered due to short steering angle the control unit and the Y636-1/1 5 tional valve, re-
circuit or open circuit for reversible component with diagnos- versible
in circuit for solenoid operator’s seat tic menu. operator’s seat
valve, steering for- not working. Check the solenoid valve.
ward (Y636–1).
171 Transistor has been Change of Check cabling between D797-2/K1:10 – VBFS, menu 5.2.15 Direc-
triggered due to short steering angle the control unit and the Y636-2/1 5 tional valve, re-
circuit or open circuit for reversible component with diagnos- versible
in circuit for solenoid operator’s seat tic menu. operator’s seat
valve, steering rear- not working. Check the solenoid valve.
ward (Y636–2).
172 Reversible opera- Front tail lights, Check bulb. D797-2/K1:25 – VBFS, menu 9.6.3 Rear
tor's seat not working Check the lamp holder. H413R/1, 7 lights
Transistor has been H413L/1
triggered due to short the control unit and the
in circuit for front tail tic menu.
light (H413R,
H413L).
Cab sliding Cab sliding not Check cabling between D797-2/K1:25 – - 9.10.4 Hydrau-
Transistor has been working. the control unit and the Y6080/1 lic sliding cab
triggered due to short component with diagnos-
valve, cab sliding
(Y6080).


and compo- tic menu
nents
173 Reversible opera- Reversal of op- Check cabling between D797-2/K1:29 – VBFS, menu 9.3.10.1 Con-
tor's seat erator’s seat not the control unit and the Y646-1/1 2 trol valve, re-
Transistor has been working. component with diagnos- versible
triggered due to short tic menu. operator’s seat
circuit or open circuit Check the solenoid valve.
in circuit for solenoid
valve, reversible op-
erator’s seat, clock-
wise (Y646-1).
Tiltable cab Cab tilt up not Check cabling between D797-2/K1:29 – MOVING- 9.10.4.5 Con-
Transistor has been working. the control unit and the Y6047/1 CAB, menu trol valve, cab
triggered due to short component with diagnos- 4 tilt
valve, cab tilt up
(Y6047).
174 Reversible opera- Reversal of op- Check the wiring between D797-2/K1:39 – VBFS, menu 9.3.10.1 Con-
tor's seat erator’s seat not the control unit and com- Y646-2/1 2 trol valve, re-
Transistor has been working. ponent with the diagnostic versible
triggered due to short menu. operator’s seat
circuit or open circuit Check component.
in circuit for solenoid
valve, reversible op-
erator’s seat, anti-
clockwise (Y646-2).
Tiltable cab Cab tilt down Check the wiring between D797-2/K1:39 – MOVING- 9.10.4.5 Con-
Transistor has been not working. the control unit and com- Y6048/1 CAB, menu trol valve, cab
triggered due to short ponent with the diagnostic 4 tilt
circuit or open circuit menu.
in circuit for solenoid Check component.
valve, cab tilt down
(Y6048).
187 Faulty signal from Joystick steer- Check cabling between D797-2/K1:16 – AUXILIARY 5.2.10 Control
steering solenoid ing or mini- the control unit and the Y636-3/2, Y636- / EL- valve joystick
valve (Y636-3, Y636- wheel not work- component with diagnos- 4/2 STEERING, steering/mini-
4). Return current ing. tic menu. menu 4 and wheel
does not match con- Check the solenoid valve. 5
trol current.


and compo- tic menu
nents
188 Faulty signal from Carriage lifting/ Check cabling between D797-2/K1:17 – ELSERV, 5.2.10 Control
solenoid valve, lift lowering not the control unit and the Y6022/2, Y6023/ menu 11 valve joystick
carriage (Y6022) and working. component with diagnos- 2 and 12 steering/mini-
solenoid valve, lower tic menu. wheel
carriage (Y6023). Check the solenoid valve.
Return current does
not match control
current.
189 Faulty signal from Side shift not Check cabling between D797-2/K1:18 – ELSERV, 7.4.5 Control
solenoid valve, side working. the control unit and the Y6020/2, Y6021/ menu 7 and valve load han-
shift left (Y6020) and component with diagnos- 2 8 dling
solenoid valve, side tic menu.
shift right (Y6021). Check the solenoid valve.
Return current does
not match control
current.
190 Faulty signal from Spreading not Check cabling between D797-2/K1:19 – ELSERV, 7.5.5 Control
solenoid valve, working. the control unit and the Y6018/2, Y6019/ menu 9 and valve load han-
spreading out component with diagnos- 2 10 dling
(Y6018) and sole- tic menu.
noid valve, spreading Check the solenoid valve.
in (Y6019). Return
current does not
match control cur-
rent.
193 Transistor has been Right front Check bulb. D797-1/K1:36 – VBFS, menu 9.6.4 Brake
triggered due to short brake light not Check the lamp holder. H410R/1 8 lights
in circuit for right
front brake light
(H410R).
tic menu.
194 Transistor has been Left front brake Check bulb. D797-1/K1:37 – VBFS, menu 9.6.4 Brake
triggered due to short light not work- Check the lamp holder. H410L/1 8 lights
circuit or open circuit ing.
in circuit for left front
brake light (H410L).
tic menu.
251 Redundant voltage - Check cabling between D791-1/K2:7 CAN/POW- 11.5.1.2 Re-
does not reach desti- tic menu. Control units


and compo- tic menu
nents
252 Redundant voltage - Check cabling between D791-1/K2:8 CAN/POW- 11.5.1.2 Re-
does not reach desti- tic menu. Control units
253 Incorrect power sup- Functions nor- Check fuse F58-3/1, D791-1/K2:1, CAN/POW- 11.5.1.4 Emer-
ply to attachment mally supplied change if needed. K2:9, K2:10 – ER, menu gency stop
control unit (D791-1). emergency stop Check cabling between F58-3/1:1 15 switch voltage
Voltage under 18 V switch voltage the control unit and the
or over 32 V. have no feed. component with diagnos-
No attachment tic menu.
functions opera-
tional.
254 Incorrect control Functions nor- Check fuse F58-3/1, D791-1/K2:11 – CAN/POW- 11.5.1.4 Emer-
switch voltage to at- mally supplied change if needed. F58-3/1:1 ER, menu gency stop
tachment control unit emergency stop Check cabling between 15 switch voltage
(D791-1). switch voltage the control unit and the
have no feed. component with diagnos-
No attachment tic menu.
functions opera-
tional.
255 Incorrect 5 V refer- – Check cabling between D791-1/K1:8 CAN/POW- 11.5.1 Power
ence voltage to pres- the control unit and the ER, menu supply
sure sensor. Voltage component with diagnos- 16
256 Transistor has been Central lubrica- Check cabling between D791-1/K1:14 – OPT, menu 9.14.1 Pump
triggered due to short tion attachment the control unit and the M693-2/1 2 unit
circuit or open circuit not working. component with diagnos-
in circuit for central tic menu.
unit for central lubri- Check the component.
cation (M693-2).
257 Transistor has been Work light at- Check bulb. D791-1/K1:1 – LIGHTS, 9.6.12 Work
triggered due to short tachment left Check the lamp holder. E404L, E404UL, menu 13 light attach-
circuit or open circuit not working. E404LL-3/1 ment
in circuit for attach-
ment work lights, left
(E404L-3).
tic menu.
258 Transistor has been Work light at- Check bulb. D791-1/K1:15 – LIGHTS, 9.6.12 Work
triggered due to short tachment right Check the lamp holder. E404R, menu 13 light attach-
circuit or open circuit not working. E404UR, ment
in circuit for attach- E404LR-3/1
ment work lights,
right (E404R-3).
tic menu.


and compo- tic menu
nents
259 DCF360-450CSG Auxiliary attach- Check bulb. D791-1/K1:28 – LIGHTS, 9.6.12 Work
Transistor has been ment work lights Check the lamp holder. E404-4L/1, menu 13 light attach-
triggered due to not working. E404-4-R/1 ment
short-circuit or open the control unit and the
circuit in circuit for component with diagnos-
auxiliary attachment tic menu.
work lights (E404-4L,
E404-4-R).
DCF90-100 Warning signal Check the buzzer. D791-1/K1:28 – ATTACH, 7.5.7 Buzzer,
Transistor has been for automatic Check cabling between H9003/1 menu 21 automatic
triggered due to short spreading not the control unit and the spreading 20'-
circuit or open circuit working. component with diagnos- 40'
in circuit for warning tic menu.
signal, automatic
spreading (H9003).
260 Transistor has been Levelling of at- Check cabling between D791-1/K1:42 – ATTACH, 7.8.4 Valve
triggered due to short tachment not the control unit and the Y637-1/1, Y637- menu 15 block, levelling
circuit or open circuit working. component with diagnos- 2/1 cylinders
in circuit for control tic menu.
valve for levelling Check the solenoid valve.
clockwise (Y637-1,
Y637-2).
261 DCF360-450CSG Extension left in Check cabling between D791-1/K1:2 – ATTACH, 7.3.2 Control
Transistor has been of attachment the control unit and the Y6046-1/1 menu 18 valve attach-
triggered due to short not working. component with diagnos- ment
valve, extension left
in (Y6046-1).
DCF90-100 Spreading left in Check cabling between D791-1/K1:16 – ATTACH, 7.3.2 Control
Transistor has been of attachment the control unit and the Y6019L/2 menu 18 valve attach-
valve, spreading left
in (Y6019L).


and compo- tic menu
nents
262 DCF360-450CSG Extension left Check cabling between D791-1/K1:3 – ATTACH, 7.3.2 Control
Transistor has been out of attach- the control unit and the Y6046-2/1 menu 17 valve attach-
triggered due to short ment not func- component with diagnos- ment
circuit or open circuit tioning. tic menu.
valve, extension left
out (Y6046-2).
DCF90-100 Spreading left Check cabling between D791-1/K1:16 – ATTACH, 7.3.2 Control
Transistor has been out of attach- the control unit and the Y6018L/2 menu 17 valve attach-
valve, spreading left
out (Y6018L).
263 DCF360-450CSG Extension right Check cabling between D791-1/K1:4 – ATTACH, 7.3.2 Control
Transistor has been in of attachment the control unit and the Y6046-3/1 menu 20 valve attach-
valve, extension right
in (Y6046-3).
DCF90-100 Spreading right Check cabling between D791-1/K1:17 – ATTACH, 7.3.2 Control
Transistor has been in of attachment the control unit and the Y6019R/2 menu 20 valve attach-
valve, spreading
right in (Y6019R).
Transistor has been out of attach- the control unit and the Y6046-4/1 menu 19 valve attach-
valve, extension right
out (Y6046-4).
Transistor has been out of attach- the control unit and the Y6018R/2 menu 19 valve attach-
valve, spreading
right out (Y6018R).


and compo- tic menu
nents
265 DCF360-450CSG Clockwise level- Check cabling between D791-1/K1:30 – ATTACH, 7.8.2 Control
Transistor has been ling of attach- the control unit and the Y6036/1 menu 16 valve attach-
triggered due to ment not component with diagnos- ment
short-circuit or open working. tic menu.
circuit in circuit for Check the solenoid valve.
control valve, level-
ling clockwise
(Y6036).
DCF90-100 Levelling left of Check cabling between D791-1/K1:19 – ATTACH, 7.8.2 Control
Transistor has been attachment not the control unit and the Y6036/2 menu 13 valve attach-
triggered due to short working. component with diagnos- ment
in circuit for levelling, Check the solenoid valve.
left (Y6036).
266 DCF360-450CSG Anticlockwise Check cabling between D791-1/K1:31 – ATTACH, 7.8.2 Control
Transistor has been levelling of at- the control unit and the Y6035/1 menu 16 valve attach-
triggered due to short tachment not component with diagnos- ment
circuit or open circuit functioning. tic menu.
in circuit for control Check the solenoid valve.
valve, levelling anti-
clockwise (Y6035).
DCF90-100 Levelling right Check cabling between D791-1/K1:19 – ATTACH, 7.8.2 Control
Transistor has been of attachment the control unit and the Y6036/2 menu 14 valve attach-
valve, levelling right
(Y6035).
267 Transistor has been Side shift left of Check cabling between DCF360- ATTACH, 7.4.2 Control
triggered due to short attachment not the control unit and the 450CSG menu 11 valve attach-
circuit or open circuit working. component with diagnos- D791-1/K1:32 – ment
in circuit for solenoid tic menu. Y6020/1
valve, side shift left Check the solenoid valve. DCF90-100
(Y6020).
D791-1/K1:18 –
Y6020/2
268 Transistor has been Side shift right Check cabling between DCF360- ATTACH, 7.4.2 Control
triggered due to short of attachment the control unit and the 450CSG menu 12 valve attach-
circuit or open circuit not working. component with diagnos- D791-1/K1:33 – ment
in circuit for solenoid tic menu. Y6021/1
valve, side shift right Check the solenoid valve. DCF90-100
(Y6021).
D791-1/K1:18 –
Y6021/2


and compo- tic menu
nents
269 Transistor has been Twistlock/lock Check cabling between D791-1/K1:7 – ATTACH, 7.9.1.2 Control
triggered due to short tongue not the control unit and the Y6040/1 menu 9 valve attach-
circuit or open circuit working. component with diagnos- ment
valve, lock twistlock/ Check the solenoid valve.
lock tongue (Y6040).
270 Transistor has been Twistlock/lock Check cabling between D791-1/K1:9 – ATTACH, 7.9.1.2 Control
triggered due to short tongue not the control unit and the Y6039/1 menu 9 valve attach-
valve, open twistlock/ Check the solenoid valve.
lock tongue (Y6039).
271 Transistor has been Twistlocks and Check cabling between D791-1/K1:10 – CAN/POW- 7.9.1.2 Control
triggered due to short spreading not the control unit and the B769-1/A, B777- ER, menu valve attach-
circuit or open circuit working. component with diagnos- 1/A, B7202L/A, 16 ment
in circuit for voltage tic menu. B7202R/A,
feed to attachment Check the sensor. B7203L/A,
position sensor. B7203R/A,
B7204L/A,
B7204R/A,
B7205L/A,
B7205R/A,
Transistor has been Sensor on at- Check cabling between D791-1/K1:10 – CAN/POW- 7.9.1.2 Control
triggered due to short tachment not the control unit and the B769-L/A, B769- ER, menu valve attach-
circuit or open circuit working. component with diagnos- R/A, B777-L/A, 16 ment
in circuit for voltage tic menu. B777-R/A,
feed to attachment Check the sensor. B7203L/A,
sensor. B7203LL/A,
B7203LU/A,
B7203LU-2/A,
B7203R/A,
B7203RL/A,
B7203RU/A,
B7203RU-2/A,
B7204L/A,
B7204R/A,
B7205LL/A,
B7205LU/A,
B7205RL/A,
B7205RU/A
272 Transistor has been Indicator light, Check bulb. D791-1/K1:25 – ATTACH, 7.9.1 Twist-
triggered due to short open twistlock/ Check the lamp holder. H562/1 menu 10 locks
circuit or open circuit lock tongue not
in circuit for indicator working.
light, twistlock/lock
tongue open (H562).
tic menu.


and compo- tic menu
nents
273 DCF360-450CSG Indicator light Check bulb. D791-1/K1:29 – ATTACH, 7.9.1 Twist-
Transistor has been alignment twist- Check the lamp holder. H563/1 menu 10 locks
triggered due to short lock not work- Check cabling between
circuit or open circuit ing. the control unit and the
in circuit for align- component with diagnos-
ment indicator light tic menu.
(H564).
DCF90-100 Indicator light, Check bulb. D791-1/K1:29 – ATTACH, 7.9.1 Twist-

Transistor has been locked twist- Check the lamp holder. H563/1 menu 10 locks
triggered due to short lock/lock Check cabling between
circuit or open circuit tongues not the control unit and the
in circuit for indicator working. component with diagnos-
light, locked twist- tic menu.
lock/lock tongues
(H563).
274 Transistor has been Indicator light, Check bulb. D791-1/K1:39 – ATTACH, 7.9.1 Twist-
triggered due to short attachment Check the lamp holder. H564/1 menu 10 locks
circuit or open circuit alignment not
in circuit for align- working.
ment indicator light
(H564).
tic menu.
287 DCF360-450CSG Extension left of Check cabling between D791-1/K1:16 – ATTACH, 7.3.2 Control
Faulty signal from attachment not the control unit and the Y6046-1/2, menu 17 valve attach-
solenoid, extension working. component with diagnos- Y6046-2/2 and 18 ment
left in (Y6046-1) and tic menu.
solenoid valve, ex- Check the solenoid valve.
tension left out
(Y6046-2). Return
current does not
match control cur-
rent.
DCF90-100 Spreading left Check cabling between D791-1/K1:16 – ATTACH, 7.3.2 Control
Faulty signal from not working. the control unit and the Y6019L/2, menu 17 valve attach-
solenoid, spreading component with diagnos- Y6019R/2 and 18 ment
left in (Y6019L) and tic menu.
solenoid valve, Check the solenoid valve.
spreading left out
(Y6018L). Return
current does not
match control cur-
rent.


and compo- tic menu
nents
Faulty signal from of attachment the control unit and the Y6046-3/2, menu 19 valve attach-
solenoid, extension not working. component with diagnos- Y6046-4/2 and 20 ment
right in (Y6046-3) tic menu.
and solenoid valve, Check the solenoid valve.
extension right out
(Y6046-4). Return
current does not
match control cur-
rent.
Faulty signal from not working. the control unit and the Y6019R/2, menu 19 valve attach-
solenoid, spreading component with diagnos- Y6018R/2 and 20 ment
right in (Y6019R) and tic menu.
solenoid valve, Check the solenoid valve.
spreading right out
(Y6018R). Return
current does not
match control cur-
rent.
289 Faulty signal from Side shift of at- Check cabling between D791-1/K1:18 – ATTACH, 7.4.2 Control
solenoid valve, side tachment not the control unit and the Y6020/2, Y6021/ menu 11 valve attach-
shift left (Y6020) and working. component with diagnos- 2 and 12 ment
solenoid valve, side tic menu.
shift right (Y6021). Check the solenoid valve.
Return current does
not match control
current.
290 Faulty signal from Attachment Check cabling between D791-1/K1:19 – ATTACH, 7.5.2 Control
solenoid, spreading spreading not the control unit and the Y6018/2, Y6019/ menu 13 valve attach-
out (Y6018) and so- working. component with diagnos- 2 and 14 ment
lenoid valve, spread- tic menu.
ing in (Y6019). Check the solenoid valve.
Return current does
not match control
current.
Faulty signal from Levelling of at- Check cabling between D791-1/K1:19 – ATTACH, 7.5.2 Control
solenoid valve, level- tachment not the control unit and the Y6035/2, Y6036/ menu 13 valve attach-
ling right (Y6036) working. component with diagnos- 2 and 14 ment
and solenoid valve, tic menu.
levelling left (Y6035). Check the solenoid valve.
Return current does
not match control
current.


and compo- tic menu
nents
291 Transistor has been Spreading out Check cabling between D791-1/K1:34 – ATTACH, 7.5.2 Control
triggered due to short of attachment the control unit and the Y6018/1 menu 13 valve attach-
circuit or open circuit not working. component with diagnos- ment
valve, spreading out Check the solenoid valve.
(Y6018).
Transistor has been Indicator light Check bulb. D791-1/K1:34 – ATTACH, 7.5.2 Control
triggered due to short for upper align- Check the lamp holder. H564UL/1 menu 23 valve attach-
circuit or open circuit ment not work- ment
in circuit for indicator ing.
light, upper align-
ment (H564UL).
tic menu.
292 Transistor has been Spreading in of Check cabling between D791-1/K1:35 – ATTACH, 7.5.2 Control
triggered due to short attachment not the control unit and the Y6019/1 menu 14 valve attach-
valve, spreading in Check the solenoid valve.
(Y6019).
298 Twistlock sensor in- Lift and spread- Check that Sensors twist- D791-1/K2:13 ATTACH, 7.9.1.7 Sensor
dicates that left twist- ing not working. lock are clean and correct- menu 8 twistlocks
lock is between open ly adjusted.
and locked position. Check cabling between
tic menu.
299 Twistlock sensor in- Lift and spread- Check that Sensors twist- D791-1/K2:15 ATTACH, 7.9.1.7 Sensor
dicates that right ing not working. lock are clean and correct- menu 8 twistlocks
twistlock is between ly adjusted.
open and locked po- Check cabling between
sition. the control unit and the
tic menu.
300 Alignment sensor in- Twistlock not Check that the alignment - ATTACH, 7.9.1.6 Sensor
dicates unreasona- working. sensors are clean and menu 7 alignment
ble distance. correctly adjusted.
Check that alignment pin
runs smoothly.
tic menu.


and compo- tic menu
nents
451 Redundant voltage - Check cabling between D795/K1:7 CAN/POW- 11.5.1.2 Re-
feed left to KID con- the control unit and the ER, menu 9 dundant volt-
trol unit (D795) does component with diagnos- age feed of
not reach destina- tic menu. control units
tion.
452 Redundant voltage - Check cabling between D795/K1:8 CAN/POW- 11.5.1.2 Re-
feed right to KID con- the control unit and the ER, menu 9 dundant volt-
trol unit (D795) does component with diagnos- age feed of
not reach destina- tic menu. control units
tion.
460 No messages re- Incorrect values Use diagnostic menu to D795/K1:10, CAN/POW- 11.6.2 Redun-
ceived on CAN-buff- in operating check CAN-bus. K1:11, K1:12, ER, menu 1, dant CAN-bus
er 1. menus. K1:13 2, 17
461 No messages re- Error codes Use diagnostic menu to D795/K1:5, K1:6 CAN/POW- 11.6.2 Redun-
ceived on CAN-buff- from other Con- check CAN-bus. ER, menu 1, dant CAN-bus
er 2. trol units cannot 2, 17
be shown.
500 Time for service. - Check that servicing has - - C Preventive

been performed. If servic- maintenance
ing has been performed
following the Kalmar In-
dustries service schedule,
reset the service indicator;
see section 8 Control sys-
tem, group 8.2.4 Service
indicator.

E Schematics 1
E Schematics
Table of Contents E Schematics

mm mm mm mm mm mm
10 Common hydraulics....................................................................................... 3
Hydraulic diagrams, compilation ............................................................................ 3
Hydraulic diagram, basic machine DCF 280-330, hydraulic servo ......................... 4
Hydraulic diagram, basic machine DCF 280-330, electric servo and freelift .......... 6
Hydraulic diagram, basic machine DCF 280-330, hydraulic servo, log grapple ..... 8
Hydraulic diagram, basic machine DCF 280-330, hydraulic servo,
brake fluid tank ..................................................................................................... 10
Hydraulic diagram, basic machine DCF370-500, hydraulic servo ........................ 12
Hydraulic diagram, basic machine DCF370-500, electric servo ........................... 14
Hydraulic diagram, basic machine DCF370-500, electric servo, brake fluid tank 16
Hydraulic diagram, separate top lift attachment ................................................... 18
11 Common electrics ........................................................................................ 20
Circuit diagram, description ................................................................................. 20
Component designations ...................................................................................... 21
Circuit diagrams, compilation ............................................................................... 22
Workshop manual DCE 280-500 VDCF02.02GB

2 E Schematics
VDCF02.02GB Workshop manual DCE 280-500

E Schematics – 10 Common hydraulics 3
mm mm mm mm mm mm
Hydraulic diagrams, compilation

page
–
Designation Drawing number

Hydraulic diagram, basic machine DCF 280-330, hydraulic servo page 4 A46139.0600
Hydraulic diagram, basic machine DCF 280-330, electric servo and freelift page 6 A46139.0500
Hydraulic diagram, basic machine DCF 280-330, hydraulic servo, log grapple A46139.0800
page 8
Hydraulic diagram, basic machine DCF 280-330, hydraulic servo, brake fluid tank A46139.0900
page 10
Hydraulic diagram, basic machine DCF370-500, hydraulic servo page 12 A46139.0700
Hydraulic diagram, basic machine DCF370-500, electric servo page 14 A46139.0300
Hydraulic diagram, basic machine DCF370-500, electric servo, brake fluid tank A46139.1000
page 16
Hydraulic diagram, separate top lift attachment page 18 A40533.0100

–
page
4
VDCF02.02GB
TILTCYLINDRAR 4 9 TRYCKREDUCERINGSVENTIL
OPTION 4 LYFTCYLINDRAR 6
TILTING CYLINDERS PRESSURE REDUCING VALVE
HYTTSKJUTNING LIFTING CYLINDERS 8 A
CABIN SLIDING
P H HDRAULSERVO SPAKAR OPTION
1 3 HYDRAULIC REMOTE CONTROL
T H SERVOFILTER 12
5 5 7 7 10
OPTION
A2 S KERHETSL SNING
VID AGGREGAT EXTRA
B1 11
A1 B2 SAFETY LOCKING WIDE FUNKTION
ATTACHMENT
2 P T
B OPTION
A
SPAKSTYRNING
13 LEVEL CONTROL STEERING
39 B1 A1 B1 A1 B1 A1 B1 A1 P2 B2 A2 TP
STOLSUMMER
15 BROMSVENTIL CHAIR BUZZER
T
BRAKE VALVE HANDBROMSLAMPA
P2 ACKUMULATOR T
B HANDBRAKE LAMP
P
P1 T
16
14 19 18
T2
T3
P LS LSPB ACC B H
24
MAX
ORBITROL 1,5 B 17
OPTION
20 21 BROMSLJUS
BRAKELIGHT
OPTION M
L R
V NDBAR F RARSTOL 23
EXTRA TURNABLE DRIWERS
FUNKTION INCHING 25
SEAT
Workshop manual DCE 280-500

22 18
E Schematics – 10 Common hydraulics
PRIORITETSVENTIL 16
31 DRIVAXEL
PRIORYTY VALVE
DRIVINGAXLE
LS CF EF P T LS
33
T 32
PP
LADDNINGSVENTIL
P
CHARGING VALVE
35
P M T OPTION
STYRCYLINDER
STEERINGCYLINDER OLJEKYLARE
34 26 OILCOOLER
L GT BROMSTRYCK
RETURFILTER LOW BRAKEPRESSURE 27
RETURNLINE TERMOBYPASSVENTIL
79 146 21 FILTER TERMOBYPASS VALVE
28
TRYCKFILTER
ANDNINGSFILTER
38 37 36 PRESSURE
AIR FILTER
FILTER
DCF 280-330, hydraulic servo
PUMP PUMP 29
30
Hydraulic diagram, basic machine
007996 (A46139.0600 ver.1)

1. Cylinder, sliding cab 21. Switch (NO), parking brake (S200)

2. Changeover valve, sliding cab 22. Accumulator charging valve
3. Side shift cylinder, sliding of forks 23. Solenoid valve parking brake (Y642)
4. Tilt cylinder 24. NO switch, brake lights (S216)
5. Load retention valve 25. Switch (NC), disengagement (S220)
6. Lift cylinder 26. Brake fluid cooler
7. Load control valve 27. Brake fluid filter
8. Pressure reducer 28. Thermal bypass valve
9. Servo pressure accumulator 29. Breather filter hydraulic oil tank
10. Servo filter 30. Hydraulic oil tank
11. Control levers 31. Directional valve, reversible operator’s seat
12. Safety locking at attachment 32. Steering cylinder
13. Control valve for lever steering/mini-wheel, solenoid valve, 33. Steering valve
steering forward (Y636-F) or steering rearward (Y636-R) 34. Oil filter
14. Brake pressure accumulator 35. Priority valve
15. Brake valve 36. Hydraulic oil pump - brakes, cooling and filtration
16. Wheel brake 37. Hydraulic oil pump - load handling
17. Drive axle block 38. Hydraulic oil pump - steering and load handling
18. Brake cylinder 39. Control valve load handling
19. Parking brake caliper
20. NC switch, brake pressure (S204)

–
page
6
VDCF02.02GB
8
8 FRILYFTCYLINDER
OPTION TILTCYLINDRAR 4 4 6 6 LYFTCYLINDRAR
TILTING FREE LIFT
HYTTSKJUTNING LIFTING CYLINDERS
CYLINDERS CYLINDER
CABIN SLIDING
1 3 B A
5 7 7
5 TP
9 TRYCKREDUCERINGSVENTIL
PRESSURE REDUCING VALVE T
P2
A2 11
B1 A
A1 B2
H
10P
13
2 P T SERVOFILTER
T H
T2
12
T3
P LS LSPB
S R S R S R S R S R S R
OPTION
C C C C C C SPAKSTYRNING
LEVEL CONTROL STEERING
39 40 B1 A1
41 B1 A1
42 B1 A1
43 B1 A1 P2 44 B2 A2 45
BROMSVENTIL
BRAKE VALVE
ACKUMULATOR B T 15
P
STOLSUMMER
CHAIR BUZZER
P1 T HANDBROMSLAMPA
16
14 HANDBRAKE LAMP
19 18
L GT BROMSTRYCK
LOW BRAKEPRESSURE
ACC B H
OPTION 24
freelift
V NDBAR F RARSTOL
C C C C C TURNABLE DRIWERS MAX
SEAT 1,5 B 17
R S R S R S R S R S R S
20 M 21 BROMSLJUS
BRAKELIGHT
L R 23
INCHING 25
ORBITROL

OPTION
22 18
EXTRA PRIORITETSVENTIL
FUNKTION PRIORYTY VALVE
31 DRIVAXEL 16
DRIVINGAXLE
LS CF EF P T LS
33
T 32
PP
STYRCYLINDER LADDNINGSVENTIL
P STEERINGCYLINDER
35 CHARGING VALVE
OPTION
P M T
OLJEKYLARE
34 OILCOOLER 26
RETURFILTER
27
79 146 21 FILTER TERMOBYPASS VALVE
28
ANDNINGSFILTER TRYCKFILTER
38 37 36 AIR FILTER PRESSURE
FILTER
PUMP PUMP 29
DCF 280-330, electric servo and
30
07995 (A46139.0500 ver

1. Cylinder, sliding cab 24. NO switch, brake lights (S216)

2. Changeover valve, sliding cab 25. Switch (NC), disengagement (S220)
3. Side shift cylinder, sliding of forks 26. Brake fluid cooler
4. Tilt cylinder 27. Brake fluid filter
5. Load retention valve 28. Thermal bypass valve
6. Lift cylinder 29. Breather filter hydraulic oil tank
7. Load control valve 30. Hydraulic oil tank
8. Freelift cylinder 31. Directional valve, reversible operator’s seat
9. Load control valve 32. Steering cylinder
10. Pressure reducer 33. Steering valve
11. Servo pressure accumulator 34. Oil filter
12. Servo filter 35. Priority valve
13. Control valve for lever steering/mini-wheel, solenoid 36. Hydraulic oil pump - brakes, cooling and filtration
valve, steering forward (Y636-F) or steering rearward (Y636- 37. Hydraulic oil pump - load handling
R)
38. Hydraulic oil pump - steering and load handling
14. Brake pressure accumulator
39. Control valve load handling
15. Brake valve
40. Solenoid valve, auxiliary function
16. Wheel brake
41. Solenoid valve - cab sliding/fork sliding right (Y6020) or left
17. Drive axle block (Y6021)
18. Brake cylinder 42. Solenoid valve, spreading in (Y6019) or out (Y6018)
19. Parking brake caliper 43. Solenoid valve, tilt in (Y6011) or out (Y6010)
20. NC switch, brake pressure (S204) 44. Solenoid valve, lift carriage (Y6005-2) or lower carriage
21. Switch (NO), parking brake (S200) (Y6004-2)
22. Accumulator charging valve 45. Solenoid valve, lift mast freelift (Y6005-1) or lower mast
23. Solenoid valve parking brake (Y642) freelift (Y6004-1)

–
page
8
VDCF02.02GB
AVSKJUTCYLINDRAR TILTCYLINDRAR GRIP CYLINDRAR LYFTCYLINDRAR
1 1 PROTRUDE CYLINDERS 2 2 TILTING CYLINDERS 4 4 GRAPPLE CYLINDERS LIFTING CYLINDERS TRYCKREDUCERINGSVENTIL
5 PRESSURE REDUCING VALVE
7 HDRAULSERVO SPAKAR
A HYDRAULIC REMOTE CONTROL
P H
T H SERVOFILTER
3 3 6 6 10
9
35 B1 A1 B1 A1 P2 B2 A2 B2 A2
12
BROMSVENTIL
BRAKE VALVE
ACKUMULATOR B T
P STOLSUMMER
CHAIR BUZZER
HANDBROMSLAMPA
P1 T
11 HANDBRAKE LAMP
17
20 19
ACC B H
L GT BROMSTRYCK 21
LOW BRAKEPRESSURE
14 MAX18
1,5 B
BROMSLJUS
BRAKELIGHT
13 M
MAN VERVENTIL L R
grapple
MAIN VALVE
16 INCHING 22
ORBITROL
28 15 19

PRIORITETSVENTIL 17
DRIVAXEL
PRIORYTY VALVE
29 DRIVINGAXLE
LS CF EF P T LS
T
PP STYRCYLINDER
STEERINGCYLINDER LADDNINGSVENTIL
P
CHARGING VALVE
30
OLJEKYLARE
P M T
OILCOOLER
RETURFILTER TRYCKFILTER
24 23
31 RETURNLINE PRESSURE TERMOBYPASSVENTIL
79 146 21 FILTER FILTER TERMOBYPASS VALVE
25
ANDNINGSFILTER
34 33 32 AIR FILTER
BROMSPUMP
BRAKE PUMP 26
PUMP PUMP
27
DCF 280-330, hydraulic servo, log
007997 (A46139.0800 ver.1)

1. Displacement cylinder 19. Brake cylinder

2. Tilt cylinder 20. Parking brake caliper
3. Load retention valve 21. NO switch, brake lights (S216)
4. Grapple cylinder 22. Switch (NC), disengagement (S220)
5. Lift cylinder 23. Brake fluid cooler
6. Load control valve 24. Brake fluid filter
7. Pressure reducer 25. Thermal bypass valve
10. Control levers 28. Steering valve
11. Brake pressure accumulator 29. Steering cylinder
12. Brake valve 30. Priority valve
13. NC switch, brake pressure (S204) 31. Oil filter
14. Switch (NO), parking brake (S200) 32. Hydraulic oil pump - brakes, cooling and filtration
15. Accumulator charging valve 33. Hydraulic oil pump - load handling
16. Solenoid valve parking brake (Y642) 34. Hydraulic oil pump - steering and load handling
17. Wheel brake 35. Control valve load handling
18. Drive axle block

–
page
10
VDCF02.02GB
TILTCYLINDRAR TRYCKREDUCERINGSVENTIL
OPTION 4 4 LYFTCYLINDRAR 6 9
TILTING CYLINDERS PRESSURE REDUCING VALVE
HYTTSKJUTNING LIFTING CYLINDERS
A
CABIN SLIDING 8P H HDRAULSERVO SPAKAR OPTION
1 3 HYDRAULIC REMOTE CONTROL
7 T H SERVOFILTER
5 7
5
10
OPTION
A2 S KERHETSL SNING
VID AGGREGAT EXTRA
B1 12
A1 B2 SAFETY LOCKING WIDE FUNKTION
ATTACHMENT
2 P T
11
B OPTION
A
SPAKSTYRNING
13 LEVEL CONTROL STEERING
44 B1 A1 B1 A1 B1 A1 B1 A1 P2 B2 A2 TP
STOLSUMMER
15 BROMSVENTIL CHAIR BUZZER
T
BRAKE VALVE HANDBROMSLAMPA
P2 ACKUMULATOR T
B HANDBRAKE LAMP
P
L GT BROMSTRYCK 16
P1 T
LOW BRAKEPRESSURE
14 19 18
T2
T3
P LS LSPB ACC B H
24
MAX
17
ORBITROL 1,5 B
OPTION OPTION
20 M 21 BROMSLJUS
BRAKELIGHT
L R
V NDBAR F RARSTOL
EXTRA
fluid tank
TURNABLE DRIWERS 23 INCHING 25

FUNKTION SEAT

22 18
PRIORITETSVENTIL 16
DRIVAXEL
PRIORYTY VALVE 34 DRIVINGAXLE

LS CF EF T LS
33 P
T 35
PP STYRCYLINDER
STEERINGCYLINDER LADDNINGSVENTIL
P
39 36 CHARGING VALVE
BYPASSFILTER
P M T OLJEKYLARE
OILCOOLER
OLJEKYLARE
38 OILCOOLER
RETURFILTER
37 26
RETURNLINE 27 TERMOBYPASSVENTIL
79 146 21 46 FILTER 2 TERMOBYPASS VALVE ANDNINGSFILTER
AIR FILTER
ANDNINGSFILTER
28
AIR FILTER 29
TRYCKFILTER
43 42 41 40 32 PRESSURE 30
FILTER
BROMSPUMP PUMP OLJEKYLNING
MAIN PUMP MAIN PUMP PUMP OILCOOLING
BRAKE PUMP 31
007998 (A46139.0900 ver.1)

DCF 280-330, hydraulic servo, brake
1. Cylinder, sliding cab 23. Solenoid valve parking brake (Y642)

2. Changeover valve, sliding cab 24. NO switch, brake lights (S216)
3. Side shift cylinder, sliding of forks 25. Switch (NC), disengagement (S220)
4. Tilt cylinder 26. Brake fluid cooler
5. Load retention valve 27. Brake fluid filter
6. Lift cylinder 28. Thermal bypass valve
7. Load control valve 29. Breather filter, brake fluid tank
8. Pressure reducer 30. Brake fluid tank
11. Safety locking at attachment 33. Steering valve
12. Control levers 34. Directional valve, reversible operator’s seat
13. Control valve for lever steering/mini-wheel, solenoid valve, 35. Steering cylinder
steering forward (Y636-F) or steering rearward (Y636-R) 36. Bypass filter
14. Brake pressure accumulator 37. Cooler hydraulic oil
15. Brake valve 38. Oil filter
16. Wheel brake 39. Priority valve
17. Drive axle block 40. Hydraulic oil pump - cooling
18. Brake cylinder 41. Hydraulic oil pump - brakes
19. Parking brake caliper 42. Hydraulic oil pump - load handling
20. NC switch, brake pressure (S204) 43. Hydraulic oil pump - steering and load handling
21. Switch (NO), parking brake (S200) 44. Control valve load handling
22. Accumulator charging valve

–
page
12
VDCF02.02GB
OPTION 9
4 4 8 A
6 6
1 P H
OPTION
3
T H 12
5 5 7 10
7
OPTION
A2
B1 EXTRA
A1 B2 FUNKTION
11
2 P T
B A
39 B1 A1 B1 A1 B1 A1 B1 A1 P2 B2 A2
13 TP
15
T
P2 B T
14 P
P1 T
16
19 18
T2
T3
ACC B H
P LS LSPB 20 21
24 MAX17
1,5 B
OPTION
OPTION M
L R
EXTRA
23
FUNKTION 31 25

22 18
32 16
35 LS CF EF P T LS
T 33
PP
P
P M T OPTION
34 26
27
79 158 21
28
36
DCF370-500, hydraulic servo
38 37
29
30
007987 (A46139.0700 ver. 1)

1. Cylinder, sliding cab 20. NC switch, brake pressure (S204)

2. Changeover valve, sliding cab 21. Switch (NO), parking brake (S200)
3. Side shift cylinder, sliding of forks 22. Accumulator charging valve
4. Tilt cylinder 23. Solenoid valve parking brake (Y642)
5. Load retention valve 24. NO switch, brake lights (S216)
6. Lift cylinder 25. Switch (NC), disengagement (S220)
7. Load control valve 26. Brake fluid cooler
8. Pressure reducer 27. Brake fluid filter
9. Servo pressure accumulator 28. Thermal bypass valve
10. Servo filter 29. Breather filter hydraulic oil tank
11. Control levers 30. Hydraulic oil tank
12. Safety locking at attachment 31. Steering valve
13. Control valve for lever steering/mini-wheel, solenoid valve, 32. Directional valve, reversible operator’s seat
steering forward (Y636-F) or steering rearward (Y636-R) 33. Steering cylinder
14. Brake pressure accumulator 34. Oil filter
15. Brake valve 35. Priority valve
16. Wheel brake 36. Hydraulic oil pump - brakes, cooling and filtration
17. Drive axle block 37. Hydraulic oil pump - load handling
18. Brake cylinder 38. Hydraulic oil pump - steering and load handling
19. Parking brake caliper 39. Control valve load handling

–
page
14
VDCF02.02GB
OPTION TILTCYLINDRAR 4 4 LYFTCYLINDRAR 6
HYTTSKJUTNING TILTING CYLINDERS LIFTING CYLINDERS
CABIN SLIDING
1 3
B A
5 5 7 7 TRYCKREDUCERINGSVENTIL
TP
PRESSURE REDUCING VALVE
T
A2 P2
A
9
B1
A1 B2
H
8P
2 P T
T H SERVOFILTER
11
10 T2
T3
S R S R S R S R S R
P LS LSPB
C C C C C OPTION
38 B1 A1 39 B1 A1
40 B1 A1
41 B1 A1 P2 42 B2 A2 SPAKSTYRNING
37 BROMSVENTIL
BRAKE VALVE
ACKUMULATOR B T
P
13 STOLSUMMER
CHAIR BUZZER
P1 T HANDBROMSLAMPA
14
12 HANDBRAKE LAMP
17 16
L GT BROMSTRYCK
LOW BRAKEPRESSURE
ACC B H
OPTION 18 19 22
V NDBAR F RARSTOL
C C C C C ORBITROL TURNABLE DRIWERS MAX 15
SEAT 1,5 B
BROMSLJUS
R S R S R S R S R S M BRAKELIGHT
L R 20
INCHING 23
16

OPTION
29 21
PRIORITETSVENTIL 14
DRIVAXEL
PRIORYTY VALVE 31
EXTRA DRIVINGAXLE
LS CF EF P T LS
FUNKTION
T 30
PP
LADDNINGSVENTIL
P
33 STYRCYLINDER CHARGING VALVE
STEERINGCYLINDER
P M T OPTION
32 TRYCKFILTER OLJEKYLARE
PRESSURE OILCOOLER
RETURFILTER FILTER
79 158 21 FILTER 25 TERMOBYPASS VALVE
ANDNINGSFILTER
26
DCF370-500, electric servo
36 35 34 AIR FILTER
24
PUMP PUMP 27
28
007993 (A46139.0300 ver.1)

1. Cylinder, sliding cab 22. NO switch, brake lights (S216)

2. Changeover valve, sliding cab 23. Switch (NC), disengagement (S220)
3. Side shift cylinder, sliding of forks 24. Brake fluid cooler
4. Tilt cylinder 25. Brake fluid filter
5. Load retention valve 26. Thermal bypass valve
6. Lift cylinder 27. Breather filter hydraulic oil tank
7. Load control valve 28. Hydraulic oil tank
8. Pressure reducer 29. Directional valve, reversible operator’s seat
9. Servo pressure accumulator 30. Steering cylinder
10. Servo filter 31. Steering valve
11. Control valve for lever steering/mini-wheel, solenoid 32. Oil filter
valve, steering forward (Y636-F) or steering rearward 33. Priority valve
(Y636-R)
34. Hydraulic oil pump - brakes, cooling and filtration
35. Hydraulic oil pump - load handling
13. Brake valve
14. Wheel brake
15. Drive axle block
16. Brake cylinder
17. Parking brake caliper (Y6021)
18. NC switch, brake pressure (S204) 40. Solenoid valve, spreading in (Y6019) or out (Y6018)
19. Switch (NO), parking brake (S200) 41. Solenoid valve, tilt in (Y6011) or out (Y6010)
20. Solenoid valve parking brake (Y642) 42. Solenoid valve, lift mast (Y6005) or lower mast (Y6004)

–
page
16
VDCF02.02GB
OPTION TILTCYLINDRAR 4 4 LYFTCYLINDRAR 6
HYTTSKJUTNING TILTING CYLINDERS LIFTING CYLINDERS
CABIN SLIDING 11
1 3
7 7 B A
5 5 TRYCKREDUCERINGSVENTIL
TP
PRESSURE REDUCING VALVE
T
A2 9 P2
B1 A
A1 B2
8P H
2 P T
T H SERVOFILTER
T2
10
T3
S R S R S R S R S R
P LS LSPB
44C OPTION
42 43C B1 A1 B1
45C
A1 B1
46C
A1 B1 A1 P2
47C B2 A2 SPAKSTYRNING
BROMSVENTIL
BRAKE VALVE
ACKUMULATOR B T
P
STOLSUMMER
13 CHAIR BUZZER
P1 T HANDBROMSLAMPA 18
12 HANDBRAKE LAMP
21 20
L GT BROMSTRYCK
LOW BRAKEPRESSURE
ACC B H
OPTION
V NDBAR F RARSTOL
22
C C C C C ORBITROL TURNABLE DRIWERS
15 MAX19
SEAT 1,5 B
BROMSLJUS
R S R S R S R S R S
14 M BRAKELIGHT
L R
fluid tank
16 INCHING 23

17 20
OPTION
PRIORITETSVENTIL 18
DRIVAXEL
EXTRA
PRIORYTY VALVE 30 DRIVINGAXLE
LS CF EF P T LS
FUNKTION
29
T 31
PP BYPASS
STYRCYLINDER
FILTER BACKVENTIL LADDNINGSVENTIL
P STEERINGCYLINDER
CHECK VALVE CHARGING VALVE
36
32 P M T OLJEKYLARE
OILCOOLER
33 TRYCKFILTER
2 PRESSURE
RETURFILTER FILTER
24
37 RETURNLINE OLJEKYLARE TERMOBYPASSVENTIL
79 158 21 46 FILTER OILCOOLER 25 TERMOBYPASS VALVE ANDNINGSFILTER
AIR FILTER
ANDNINGSFILTER
26
AIR FILTER 27
41 40 39 38 28
34
MAIN PUMP MAIN PUMP BROMSPUMP PUMP OLJEKYLNING
BRAKE PUMP PUMP OILCOOLING 35
DCF370-500, electric servo, brake
007999 (A46139.1000 ver.01)

1. Cylinder, sliding cab 25. Brake fluid filter

2. Changeover valve, sliding cab 26. Thermal bypass valve
3. Side shift cylinder, sliding of forks 27. Breather filter, brake fluid tank
4. Tilt cylinder 28. Brake fluid tank
5. Load retention valve 29. Steering valve
6. Lift cylinder 30. Directional valve, reversible operator’s seat
7. Load control valve 31. Steering cylinder
8. Pressure reducer 32. Bypass filter
9. Servo pressure accumulator 33. Cooler hydraulic oil
10. Servo filter 34. Breather filter hydraulic oil tank
11. Control valve for lever steering/mini-wheel, solenoid 35. Hydraulic oil tank
valve, steering forward (Y636-F) or steering rearward 36. Priority valve
(Y636-R)
37. Oil filter
38. Hydraulic oil pump - cooling
13. Brake valve
39. Hydraulic oil pump - brakes
14. NO switch, brake pressure (S204)
40. Hydraulic oil pump - load handling
15. Switch (NO), parking brake (S200)
16. Solenoid valve parking brake (Y642)
18. Wheel brake
19. Drive axle block (Y6021)
20. Brake cylinder 45. Solenoid valve, spreading in (Y6019) or out (Y6018)
21. Parking brake caliper 46. Solenoid valve, tilt in (Y6011) or out (Y6010)
22. NO switch, brake lights (S216) 47. Solenoid valve, lift mast (Y6005) or lower mast (Y6004)
23. Switch (NC), disengagement (S220)
24. Brake fluid cooler

18 E Schematics – 10 Common hydraulics
Hydraulic diagram, separate top lift

page
–
attachment
2
3
1
4 5
7
007986 (A40533.0100 Ver.1)

2. Twistlock cylinder
3. Hydraulic oil pump, attachment
4. Solenoid valve, twistlocks (Y6044)
5. Solenoid valve, spreading (Y6046)
6. Solenoid, damping (Y6046-2)
7. Spreading motor
8. Hydraulic oil connection to fork spreading section

20 E Schematics – 11 Common electrics
11 Common electrics
mm mm mm mm mm mm
Circuit diagram, description

page
–
A circuit diagram is divided into circuit names (drawing numbers) and

consists of a set of numbered pages.
The following is an explanation of symbols in circuit diagrams:
• X is connection terminal (followed by number)
• Designation 353-2
353 is component designation (see Component designations
page 21 for description of each component). 2 indicates that it is
the second component of this type in the specific diagram.
• Sensors etc. are drawn in resting position on circuit, that is, with-
out voltage.
• Colour cables:
White cable = ground signal
Grey cable = other cables
• Fuse box, for example F58, means fuse box with 8 fuses
• An arrow symbol indicates a reference to another circuit diagram
• 20015.0001 electrical drawings-post designations K-standard.
K-standard 1: norms, rules
K-standard 2: cables, general physical
K-standard 5: Designation and marking system, item designations
circuit drawings
• Ground connection:
1: X37-A is ground connection in the electrical distribution box. A
connection terminal for ground. Frame connection-connection ter-
minal to chassis.
2: Zero reference is found in control units.

E Schematics – 11 Common electrics 21
Component designations
page
–
The components in circuit diagrams have a prefix and number, the

prefix describes the type of component, the number which component.
Component list with component number, prefix and designation is pro-
vided as an appendix after the circuit diagrams.
Prefix Description
A Unit, sub-unit. Example: amplifier with separate components.
B Converter from non-electric to electric signals or vice versa. Example: inductive sensor.
C Capacitor.
D Binary element, delay unit, memory. Example: control unit.
E Lighting and heating unit.
F Protective device. Example: fuse.
G Alternator, power supply device. Example: fuse.
H Signal device. Example indicator light.
K Relay, connector.
L Inductance, reactance.
M Motor. Example: electric motor.
N Analogue element. Example: operation amplifier.
P Measuring instrument, testing equipment. Example: operating hour gauge.
Q Electrical connector for power circuit. Example: circuit breaker.
R Resistor. Example: potentiometer.
S Electric switch for control circuit, selector. Example: switch.
T Transformer.
U Modulator, converter or transformer. Example: frequency converter.
V Conduit, semiconductor. Example: diode, transistor.
W Transmission route, wave-guide, antenna. Example: cable, bus bar.
X Outlet/socket, connecting device Example: connection terminal.
Y Electrically controlled mechanical device: Example: solenoid valve, hydraulic valve.
Z Transformer, network, hybrid, filter, equaliser, limiter. Example: cable balancing network.

Circuit diagrams, compilation

page
–
Circuit diagrams are attached as an appendix in the following order.

The circuit diagram for the basic machine has drawing number
A49226.0100.
Sheet Designation
0.0-1 Cross-reference list
0.1-1 Truth table opt.
1.0-1 Circuit, drivetrain, engine
1.0-2A Circuit, Volvo TAD722VE engine
1.0-2B1 Circuit, Cummins QSM11 engine
1.0-2B2 Circuit, Cummins QSM11 engine
1.0-2C Circuit, Volvo TAD950VE, TWD 1240VE, TAD1250VE engine
1.0-2D Circuit, Volvo TAD760VE engine
1.0-2E1 Circuit, Cummins QSB6.7 engine
1.0-2E2 Circuit, Cummins QSB6.7 engine
2.0-1 Circuit, drivetrain gearbox
2.0-2A1 Circuit, TE32 gearbox
2.0-2B1 Circuit, TE17 gearbox
4.0-1 Circuit, brake system
4.8-1 Circuit, brake oil cooling
5.2-1 Circuit, lever/mini-wheel steering
5.2-2 Circuit, lever/mini-wheel steering
7.0-1 Circuit, electric servo levers
7.0-2 Circuit, electric servo joystick
7.0-4 Circuit, accessory attachment
7.0-5 Circuit, accessory attachment
7.0-7 Circuit, lifting height
7.2-1 Circuit, lift/lower electric servo

Sheet Designation
7.2-2 Circuit, freelift sensors
7.2-3 Circuit, freelift sensors
7.2-6 Circuit, mast valves
7.3-1 Circuit, gantry attachment
7.4-1 Circuit, side shift, electric servo
7.4-2 Circuit, side shift gantry
7.5-1 Circuit 20-40, 30-35 stop
7.5-2 Circuit, spreading gantry
7.5-3 Circuit, 20’-40’ opt.
7.7-1 Circuit, tilt electric servo
7.7-2 Circuit, tilt indication
7.8-1 Circuit, levelling gantry
7.9-1 Circuit, twistlock
7.9-2 Circuit, sensor gantry
7.9-3 Circuit, pliers Avesta
7.10-1 Circuit, 5th function, electric servo
7.10-2 Circuit, option gantry
8.2-1 Circuit, bypassing
8.2-2 Circuit, overload protection
8.2-3 Circuit, mast sensor OLS
8.2-4 Circuit RMI
9.0-1 Circuit, std. opt.
9.1-1 Circuit, std. opt.
9.1-2 Circuit, hour counter
9.3-1 Circuit, seat heating
9.3-2 Circuit, air suspension seat
9.3-3 Circuit, reversible operator’s seat
9.4-1 Circuit, climate system
9.4-2 Circuit, climate system
9.5-1 Circuit, wipers

Sheet Designation
9.6-1 Circuit, work lights 20’-40’
9.6-2 Circuit, work lights, carriage
9.6-3 Circuit, work lights, mast
9.6-4 Circuit lighting
9.6-7 Circuit, direction indicators & hazard
9.6-8 Circuit, interior lighting
9.6-9 Circuit, work light, option
9.6-10 Circuit, work light, option
9.6-11 Circuit, entry lighting
9.6-12 Circuit, auxiliary lighting, attachment
9.6-13 Circuit, work light, lamp hood, option
9.6-14 Circuit, carriage work light, option
9.7-1 Circuit, alarm, audible signals
9.7-2 Circuit, back-up alarm
9.7-3 Circuit, compressor horn
9.7-4 Circuit for horn, servo panel
9.8-1 Circuit, radio
9.8-2 Circuit, printer
9.9-1 Circuit, rearview mirror heating
9.9-2 Circuit, camera
9.10-1 Circuit, cab tilt/sliding cab
9.14-1 Circuit, central lubrication
10.4-1 Circuit, hydraulic pump disengagement
10.6-1 Circuit, hydraulic oil cooling
11.5-1 Circuit, current
11.5-6 Circuit, emergency stop switch
11.5-7 Circuit, 24/12 V
11.5-8 Circuit, 24 V socket

Sheet Designation
11.5-9 Circuit, option, ground power
11.5-10 Circuit, option, ground
11.5-11 Circuit, option, ground
11.6-1 Circuit CAN bus ground
11.6-2A Circuit, CAN bus KDU opt.
11.6-2B Circuit, CAN bus KDU opt.
11.6-2C Circuit, CAN bus KDU opt.
The circuit diagrams are included as an appendix in the following or-

der. The circuit diagram for the separate top lift attachment has draw-
ing number A44659.0100.
Sheet Designation
1/5 Circuit, top lift attachment 20-40


1 2 3 4 5 6 7 8
A A
B B
C Kretsar DCF300, DCE300330 C
Wiring DCF 300, DCE300330
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
Ref. Benämning Produkt/Product Blad/Sheet

Nr Ändring Ändring nr Datum Sign. Datum/Date Huvudnr./Project no.
Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Kretsar DCF370, DCE300330 DCF300,DCE300 0
CJS 050128 A47137.0100
Name
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Added connection automatic display change, 9.9_2 071520 TKB 071030 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring DCF370, DCE300330 A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
D7901
K1 1:11:6 /11.5_4.C5 K6 6:1 /9.4_1.B1 LAMP INST. ILLUMINATION PWM K9 9:1 /5.2_1.A2 SWITCHES ARM REST 24V reference
6:2 /9.6_2.B8 SW WLIGHTS CARRIAGE Input 9:2 /5.2_1.C2 LAMP F/R ARM REST 1.5A
K2 2:1 /9.5_1.C1 MOTOR FRONT WIPER 5A 6:3 /9.6_3.B8 SW WORK LIGHTS MAST Input 9:3 /5.2_1.C8 SW REVERSE ARM REST Input
2:2 /9.4_2.C1 MOTOR HEATING FAN PWM 6:4 /9.6_4.C8 SWITCH ROT. BEACON Input 9:4 /5.2_1.B8 SW FORWARD ARM REST Input
2:3 /9.4_2.E1 MOTOR RECIRCULATION 1.5 6:5 /9.6_4.A8 SWITCH MAIN LIGHT Input 9:5 /5.2_1.B8 SW ACT. MICRO STEERING Input
2:4 /9.5_1.D1 MOTOR REAR WIPER 5A 6:6 /9.3_1.B8 SWITCH SEAT HEATER Input
2:5 /9.6_4.E1 MOTOR ROT. BEACON 5A 6:7 /9.1_1.E8 SWITCH S2 OPT. Input 9:6 /5.2_1.D8 POT. MICRO STEERING 0V reference
2:6 /9.6_6.A1 REVERSING LIGHT LEFT 5A 6:8 /9.1_1.D8 SWITCH S3 OPT. Input 9:7 /5.2_1.D2 POT. MICRO STEERING Analog reference 5V
2:7 /9.6_6.B1 REVERSING LIGHT RIGHT 5A 9:8 /5.2_1.D8 POT. MICRO STEERING (P6) Analog Input
2:8 /9.4_2.D8 LOGIC SUPPLY HEAT FAN 6:9 /9.1_1.B8 SWITCH S4 OPT. Input 9:9 /5.2_1.E8 POT. MIC STEER/6TH LEV (P7)Analog Input
6:10 /9.6_1.A8 SW WORK LIGHTS MAST Input 9:10 /5.2_1.A8 SWITCH HORN ARM REST Input
B 6:11 /1.0_1.A8 POT. ACCELERATOR 1 Analog Input B
K4 4:1 /9.4_2.B1 MOTOR WATER VALVE 0.5A
4:2 /9.4_2.B1 MOTOR WATER VALVE 0.5A 6:12 /1.0_1.B8 POT. ACCELERATOR 2 Analog Input
4:3 /9.4_2.A1 MOTOR DRAUGHT VALVE 0.5A 6:13
4:4 /9.4_2.A1 MOTOR DRAUGHT VALVE 0.5A 6:14 /2.0_1.C8 PEDAL DECLUTCHING Input K10 10:1
4:5 /9.4_2.B1 POT. DRAUGHT/WAT. VALVE Analog reference 5V 6:15 10:2
4:6 /9.4_2.B8 POT. DRAUGHT/ WAT VALVE 0V reference 6:16 SEE K11:13 10:3 /7.0_4.B8 SENSOR ALIGNMENT Input
4:7 /9.4_2.B8 POT. DRAUGHT VALVE Analog Input 10:4 /9.4_2.C8 POT. WATER VALVE Analog Input
K7 7:1 /7.0_1.A8 POTENTIOM. EL. SERVO 0V reference 10:5 Input
4:8 /9.4_1.D8 SENSOR TEMP. INDOOR Reostat in 7:2 /7.0_1.A1 POTENTIOM. EL. SERVO Analog reference 5V 10:6 Input
4:9 /9.4_1.F8 SENSOR TEMP. AMBIENT Reostat in 7:3 /7.0_1.A8 POT. LIFT / LOWER (P1) Analog Input 10:7 /9.3_1.C2 RELAY SEAT HEATER 0.5A
4:10 /9.4_1.E8 SENSOR TEMP. FAN AIR Reostat in 7:4 /7.0_1.B8 POT. TILT (P2) Analog Input 10:8 /9.6_1.B1 CONTAINER LIGHT 40 0.5A
4:11 /9.4_1.E8 SENSOR DEICING SENSOR Reostat in 7:5 /7.0_1.C8 POT. SIDE SHIFTING (P3) Analog Input
4:12 /9.4_1.F1 SENSORS AIRCONDITION 0V reference 7:6 /7.0_1.D8 POT. SPREADING (P4) Analog Input 10:9 /9.1_2.B1 HOUR MET/RELAY AIR SEAT 0.5A
4:13 /9.5_1.C8 MOTOR FRONT WIPER Input 7:7 /7.0_1.E8 POT. EXTRA (P5) Analog Input 10:10 /11.5_3.E1 RELAY K3151 0.5A
4:14 /9.5_1.C1 MOTOR FRONT WIPER 24V reference 7:8 /9.6_1.D1 CONTAINER LIGHT 20 0.5A 10:11 /11.5_6.C1 RELAY K30091 0.5A
10:12 /11.5_6.B1 RELAY K30092,K3002,K3007 0.5A
C K5 5:1 /9.1_1.B1 SWITCHES LEFT PANEL 24V reference 7:9 /7.0_2.C1 IND. LOCKED LEVELLING 0.5A 10:13 /9.5_1.E1 MOTOR WASHER 3A C
5:2 7:10 /7.0_5.B1 RELAY ACTIVATE TW 0.5A 10:14 /9.5_1.E1 MOTOR ROOF WIPER 1.5A
5:3 /7.0_4.F2 OVERRIDE ALIGNMENT PWM (NPN) 7:11 /7.0_5.C1 RELAY ACTIVATE SPREAD 0.5A 10:15
5:4 /9.5_1.F8 MOTOR WASH REAR/ROOF PWM (NPN) 7:12 /7.0_2.B1 SWITCHES EL. SERVO Analog Reference 24V 10:16 /11.5_3.F1 RELAY K3152 0.5A
5:5 /9.6_7.B8 SWITCH LAMP HAZARD PWM (PNP) 7:13 /7.5_1.B8 SWITCH SPREADING 2040 Input
5:6 /9.6_7.A8 SWITCH HAZARD Input 7:14 /7.5_1.A8 SWITCH SPREADING 4020 Input K11 11:1 /11.5_3.C8 SWITCH IGNITION Input
5:7 /9.4_1.B8 FAN SPEED Analog Input 7:15 /7.9_1.C8 SWITCH UNLOCK TW Input 11:2 /9.6_8.A8 INTERIOR LIGHT Input
7:16 /7.0_2.C8 SWITCH PISTOL Input 11:3 /9.6_8.B8 SWITCH BREAK CAB DOOR Input
5:8 /9.4_1.C8 TEMPERATURE Analog Input 11:4 /9.6_11.B8 SWITCH STEP IN LIGHT Input
5:9 /9.4_1.C8 DRAUGHT VALVE Analog Input K8 8:1 /7.8_1.E7 SWITCH LOCK LEVELLING Input 11:5
5:10 /9.4_1.D8 POT. FAN / TEMP / DEFROST 0V reference 8:2 /7.0_2.C8 SWITCH LOCK TILT Input 11:6 /9.6_8.D1 LAMP INTERIOR LIGHT 1.5A
5:11 /9.4_1.B1 POT. FAN / TEMP / DVALVE Analog reference 5V 8:3 /8.2_1.B8 SWITCH OVERRIDE Input 11:7 See K13 REDUNDANT POWER Dig out
5:12 /1.0_1.A8 POT. ACCELERATOR 0V reference 8:4 /11.5_6.A8 SW. OPERATING POWER Input
5:13 /1.0_1.A1 POT. ACCELERATOR Analog reference 5V 8:5 /4.0_1.B8 SWITCH PBRAKE OPEN Input 11:8 See K13 REDUNDANT POWER Dig out
5:14 /7.0_4.F8 OVERRIDE ALIGNMENT Input (K10:3) 8:6 /9.3_3.A8 SWITCH REV. SEAT C.W Input 11:9 See K13 REDUNDANT POWER Dig out
8:7 /9.3_3.B8 SWITCH REV. SEAT C.C.W Input 11:10 See K13 REDUNDANT POWER Dig out
D 8:8 /7.0_4.D8 SENSOR LOCK TW Input 11:11 /9.7_1.B2 HORN 3A D
11:12 /9.7_1.D2 SWITCH SEAT 24V reference
8:9 /7.0_4.C8 SENSOR UNLOCK TW Input
secuted.
11:13 /11.5_6.E8 FEEDBACK K2 Input
8:10 /7.5_1.C8 SWITCH 3035 STOP Input 11:14 /9.7_1.D8 SWITCH SEAT Input
8:11 /7.5_3.B7 SWITCH AUT. 2040 Input
8:12 /7.9_1.A8 SWITCH LOCK TW Input K12 12:1 /9.5_1.D1 MOTOR REAR WIPER 24V reference
8:13 /4.0_1.A8 SWITCH PBRAKE LOCKED Input 12:2 /9.5_1.D8 MOTOR REAR WIPER Input
8:14 /9.1_1.A8 SWITCH S1 OPT. Input 12:3 /9.5_1.E1 MOTOR ROOF WIPER 24V reference
8:15 /9.3_3.B1 LIGHT SW. S169/S1010 1.5A 12:4 /9.5_1.E8 MOTOR ROOF WIPER Input
8:16 /7.9_1.C2 SWITCH ELSERVO PANEL 24V reference
K13 13:113:12 /11.6_1.D6 CANBUS
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Korsreferens lista DCF300,DCE300 0.0_1
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 Uppdaterade efter senaste ändring 071520 TKB 071030 6
Crossreference list A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
D7971
Pin Number Drawing Function Type

B B
Power /11.5_4.B5
CAN /11.6_1.E8
2:6 /4.8_1.A8 SENSOR BRAKE OIL TEMP. Temperature Input
2:11 /11.5_4.A5 Emergency stop Input
KDU contact K2
2:13 /10.6_1.A8 SENSOR HYDR. OIL TEMP. Temperature Input
2:15 /1.0_1.F8 SENSOR FUEL LEVEL Reostat In
2:16 /1.0_1.E1 D+ D+
C C
D7971
Pin Number Drawing Function Type Pin Number Drawing Function Type
1:1 /9.6_3.D1 LAMPS WORK LIGHT MAST 6A 1:21 /8.2_2.A7 SENSOR HYDR. SCALE LIFT Analog In 05V

1:2 /9.6_5.C1 SIDE POSITION LIGHT 1.5A 1:22 /8.2_2.D7 SENSOR HYDR. SCALE TILT Analog In 05V
1:3 /4.8_1.C1 RELAY COOLING FAN BRAKE OIL 1.5A 1:23 /7.7_2.D8 SENS.TILT ANGLE/FEEDBACK BRK FAN Analog In 05V
1:4 /7.2_1.C1 VALVE LIFT / LOWER 1.5A 1:24 /7.2_6.E8 SENSOR MAST POS/REGENERATING Analog In 05V
1:5 /7.7_1.C1 VALVE TILT 1.5A 1:25 /9.4_2.E1 COMPRESSOR AIRCONDITION 1.5A
1:6 /8.2_2.C7 SENSOR HYDR. SCALE 0V Ref 1:26 /7.0_7.C8 SENSOR CAB TILT Dig In / 1.5A
1:7 /9.6_6.C1 BRAKE LIGHT LEFT 1.5A 1:27 /2.0_1.C8 SWITCH DECLUTCHING Analog In 05V
1:8 /8.2_2.A1 SENSOR HYDR. SCALE Analog Ref 5V 1:28 /9.6_5.B1 LAMP DIPPED LIGHT 6A
1:9 /9.6_6.C1 BRAKE LIGHT RIGHT 1.5A 1:29 /9.4_2.F1 COMPRESSOR AIRCONDITION 1.5A
1:10 /9.7_2.B1 REVERSING ALARM 1.5A 1:30 /9.6_7.E1 LAMP DIRECTION LEFT 2.5A
D 1:11 /7.2_2.C7 MAST DOWN / REGENERATING LIFT Dig In / 1.5A 1:31 /9.6_7.D1 LAMP DIRECTION RIGHT 2.5A
D
1:12 /7.2_2.B7 CARRIAGE UP / REGENERATING LIFT Dig In / 1.5A 1:32 /1.0_1.F1 RELAY STARTING KEY 1.5A
KDU contact K1
KDU contact K1
secuted.
1:13 /4.0_1.D8 PRESSURE SWITCH ACCU. TANK Analog In 05V 1:33 /9.6_6.D1 REAR LIGHTS 1.5A
1:14 /10.6_1.B1 MOTOR COOLING FAN HYDR. OIL 10A 1:34 /4.0_1.E1 VALVE PARKING BRAKE 1.5A
1:15 /9.6_5.C1 HEAD LIGHT 6A 1:35 /10.4_1.D2 PUMP ATTACHMENT 1.5A
1:16 /7.2_1.C8 VALVE LIFT / BLOCK LIFT PWM 1:36 /8.2_3.C1 MAST POSITION 1.5A
1:17 /7.2_1.D8 VALVE LOWER / BLOCK LOWER PWM 1:37 /8.2_3.C8 MAST POSITION Dig In / 1.5A
1:18 /7.7_1.D8 VALVE TILT IN PWM 1:38 0V Ref
1:19 /7.7_1.C8 VALVE TILT OUT PWM 1:39 /10.4_1.C2 VALVE PUMP 2 1.5A
1:20 /9.6_5.E8 PRESSURE SWITCH BRAKE LIGHT Analog In 05V 1:40 /9.4_1.A8 PRESSURE SW. REFRIDGE Dig In / 1.5A
1:41 /4.0_1.C8 PRESSURE SWITCH PBRAKE Analog In 05V
1:42 /9.0_1.C2 CENTRAL LUB. / WORK LIGHT OPT. 6A
E E
F F

Ruta Sign.
Sq.
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
D7972
Power /11.5_5.D5
CAN /11.6_2C.E3
2:6 Temperature Input
2:11 /11.5_5.C4 Emergency stop Input
KDU contact K2
B B
2:15 Reostat In
2:16 D+
D7972
Pin Number Drawing Function Type Pin Number Drawing Function Type

C C
1:1 /9.3_5.C1 HEAD LIGHT REAR 6A 1:21 /11.5_10.B8 OPT. Analog In 05V
1:2 /5.2_2.B1 VALVE MICRO STEERING RIGHT 1.5A 1:22 /11.5_10.B8 OPT. Analog In 05V
1:3 /5.2_2.C1 VALVE MICRO STEERING LEFT 1.5A 1:23 /11.5_10.C8 OPT. Analog In 05V
1:4 /7.10_1.B1 VALVE EXTRA FUNCT. OUT 1.5A 1:24 /11.5_9.C1 OPT. Analog In 05V
1:5 /7.10_1.C1 VALVE EXTRA FUNCT. IN 1.5A 1:25 /9.3_5.D1 LAMP REAR LIGHT FRONT 1.5A
1:6 /11.5_10.B1 OPT. 0V Ref 1:26 /11.5_11.D1 OPT. Dig In / 1.5A
1:7 /9.3_3.D1 SWITCHES SEAT POS. F/R 1.5A 1:27 Analog In 05V
1:8 /11.5_10.A1 OPT. Analog Ref 5V 1:28 /11.5_9.B1 OPT. 6A
1:9 /9.3_6.B1 VALVE STEERING FORWARD 1.5A 1:29 /9.3_7.A1 VALVE SEAT ROTATION C.W 1.5A
1:10 /9.3_6.C1 VALVE STEERING REVERSE 1.5A 1:30 /7.4_1.C1 VALVE SIDESHIFT RIGHT 2.5A
1:11 /11.5_11.B1 OPT. Dig In / 1.5A 1:31 /7.4_1.B1 VALVE SIDESHIFT LEFT 2.5A
1:12 /11.5_11.C1 OPT. Dig In / 1.5A 1:32 /7.5_1.E1 VALVE SPREADING IN 1.5A
KDU contact K1
KDU contact K1
1:13 /9.3_3.C8 SWITCH SEAT POS. F Analog In 05V 1:33 /7.5_1.E1 VALVE SPREADING OUT 1.5A
1:14 /11.5_9.A1 OPT. 10A 1:34 /9.3_7.B1 DAMPING TURNABLE SEAT 1.5A
1:15 /9.3_5.B1 LAMP DIPPED LIGHT REAR 6A 1:35 /9.3_7.C1 BRAKE TURNABLE SEAT 1.5A
D 1:16 /5.2_2.B8 VALVE MICRO STEERING PWM 1:36 /9.3_4.C2 LAMP BRAKE LIGHT FORWARD RIGHT 1.5A D
1:17 /7.10_1.B8 VALVE EXTRA FUNCT. PWM 1:37 /9.3_4.B2 LAMP BRAKE LIGHT FORWARD LEFT 1.5A
1:18 /7.4_1.B8 VALVE SIDESHIFT PWM 1:38 0V Ref
secuted.
1:19 /7.5_1.E8 VALVE SPREADING PWM 1:39 /9.3_7.B1 VALVE SEAT ROTATION C.C.W 1.5A
1:20 /9.3_3.D8 SWITCH SEAT POS. R Analog In 05V 1:40 /11.5_11.D1 OPT. Dig In / 1.5A
1:41 /11.5_10.A8 OPT. Analog In 05V
1:42 /11.5_9.D1 OPT. 6A
E E
F F

Ruta Sign.
Sq.
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
D791
Power /11.5_5.C5
CAN /11.6_2B.C3
B 2:6 Temperature Input B
2:11 /11.5_5.B4 Emergency stop Input
KDU contact K2
2:15 Reostat In
2:16 D+
D791
C Pin Number Drawing Function Type Pin Number Drawing Function Type C

1:1 /9.6_2.C2 WORK LIGHT LEFT 6A 1:21 /7.10_2.B7 OPT. Analog In 05V
1:2 /7.3_1.B2 PROJECTING LEFT IN 1.5A 1:22 /7.9_2.D8 SENSOR UNLOCKED TW. LEFT Analog In 05V
1:3 /7.3_1.B2 PROJECTING LEFT OUT 1.5A 1:23 /7.9_2.E8 SENSOR LOCKED TW. LEFT Analog In 05V
1:4 /7.3_1.C2 PROJECTING RIGHT IN 1.5A 1:24 /7.9_2.B8 SENSOR LOCKED TW. RIGHT Analog In 05V
1:5 /7.3_1.D2 PROJECTING RIGHT OUT 1.5A 1:25 /7.9_1.C2 LAMP UNLOCKED TW 1.5A
1:6 /7.10_2.C7 OPT. 0V Ref 1:26 /7.9_2.C8 SENSOR ALIGNMENT REAR RIGHT Dig In / 1.5A
1:7 /7.9_1.E2 VALVE LOCK TWISTLOCK 1.5A 1:27 /7.9_2.E8 SENSOR ALIGNMENT REAR LEFT Analog In 05V
1:8 /7.10_2.B2 OPT. Analog Ref 5V 1:28 /7.5_3.D1 WARN. SIGNAL AUT. SPREADING 6A
1:9 /7.9_1.F2 VALVE UNLOCK TWISTLOCK 1.5A 1:29 /7.9_1.D2 LAMP LOCKED TW 1.5A
1:10 /7.9_2.C2 SENSORS ATTACHMENT 1.5A 1:30 /7.8_1.B2 VALVE LEVELLING LEFT 2.5A
1:11 /7.10_2.E7 SENSOR OPT. Dig In / 1.5A 1:31 /7.8_1.A2 VALVE LEVELLING RIGHT 2.5A
1:12 /7.5_2.D7 SENSOR DAMPING 2040 Dig In / 1.5A 1:32 /7.4_2.B2 VALVE SIDESHIFT LEFT 1.5A
KDU contact K1
KDU contact K1
1:13 /7.9_2.D8 SENSOR ALIGNMENT FRONT LEFT Analog In 05V 1:33 /7.4_2.C2 VALVE SIDESHIFT RIGHT 1.5A
1:14 /9.14_1.D2 PUMP CENTRAL LUBRICATION 10A 1:34 /7.5_2.B2 VALVE SPREADING OUT 1.5A
D 1:15 /9.6_2.D2 WORK LIGHT RIGHT 6A 1:35 /7.5_2.C2 VALVE SPREADING IN 1.5A D
1:16 /7.3_1.B7 PROJECTING LEFT PWM 1:36 /7.10_2.C2 OPT. 1.5A
1:17 /7.3_1.C7 PROJECTING RIGHT PWM 1:37 /7.10_2.D2 OPT. 1.5A
secuted.
1:18 /7.4_2.B7 VALVE SIDESHIFT PWM 1:38 0V Ref
1:19 /7.5_2.B7 VALVE SPREADING PWM 1:39 /7.9_1.D2 LAMP ALIGNMENT 1.5A
1:20 /7.5_2.E7 SENSOR 3035 STOP Analog In 05V 1:40 /7.9_2.A8 SENSOR ALIGNMENT FRONT RIGHT Dig In / 1.5A
1:41 /7.9_2.B8 SENSOR UNLOCKED TW. RIGHT Analog In 05V
1:42 /7.8_1.C2 VALVE UNLOCK LEVELLING 6A
E E
F F

Ruta Sign.
Sq.
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
S1053 S1051 M693
Choice: opt Choice: opt Central
mast fenders lubrication
Val: opt Val opt Central
KDU stativ skärmar S1993 S1994 smörjning
D7971 alt 1 X213

C D7971 alt 2 X213 C
D7971 alt 3 X213
D7971 alt 4 X213
D7971 + alt 5 X249 X240 X213
D7972
D7971 + alt 6 X249 X240 X213
D7972
D7971 + alt 7 X213 X249 X240
D D7972 D
alt 8
secuted.
D7971 + X240/ X213
D7972 X249
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Sanningstabell opt. DCF300,DCE300 0.1_1
CJS 050316 A47137.0100
Name
R
E³ DRAWING
1 Ny konstruktion / New design 071520 TKB 071030 6
Truth table opt. A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
X005 X040m X040f X066f X066f X040f X040m X005

Analog reference 5V K5:13 13 00513A 4 4 A0404 2 5V 0V 3 A0405 5 5 00512A 12 K5:12 0V reference
D7901 / 9.3_3.D2 / 9.3_3.E2 D7901
/0.0_1.D1 /0.0_1.D1
POT. ACCELERATOR POT. ACCELERATOR
X038f X038f
A 00513B 5 6 00512B A
X6901f X006
B6901 BK 2 2 00611 11 K6:11 Analog Input
D7901
X6901f /0.0_1.B4
3
00513C 1 1 RD 1 2 WH 3 3 00512C
POT. ACCELERATOR 1
ACCELERATOR
X016
24V D7902/2:1 0161 1 K2:1 Input
/ 11.5_3.C7 D7902 X066f X040f X040m X006
/11.5_4.F4 D7901/6:12 1 A0403 3 3 00612A 12 K6:12 Analog Input
/ 9.3_3.D6 D7901
SWITCH STARTER /0.0_1.B4
B POT. ACCELERATOR 2 B
X016 X038f
24V D7902/2:2 0162 2 K2:2 Input 8 00612B
/ 11.5_3.C7 D7902
/11.5_4.F4
SWITCH PREHEAT
/ 1.0_2B1.B1
X210f / 1.0_2C.C2
581/3:1 2101 1 581/3:1
/ 11.5_1.B5 / 1.0_2D.B2
/ 1.0_2B2.B7
2102
/ 1.0_2D.B2
2 CHASSIS
/ 1.0_2E2.B7
C / 1.0_2A.B2 C
/ 1.0_2B1.B1
/ 1.0_2C.C2
2033 30 / 1.0_2D.B2
CAN_J1939_+ 3 CAN_J1939_+
/ 11.6_1.C2 / 1.0_2E1.F1
2034
/ 1.0_2A.B2
/ 1.0_2B1.B1
/ 1.0_2C.C2
/ 1.0_2D.B2
2034 30 / 1.0_2E1.F1
CAN_J1939_ 4 CAN_J1939_
/ 11.6_1.C2 / 2.0_2B1.A2
2033
X210f / 1.0_2A.E2
D 581/4:1 2105A 5 581/4:1 D
/ 11.5_1.C5 / 1.0_2B1.B1
secuted.
/ 1.0_2A.B2
/ 1.0_2B1.C1
/ 1.0_2C.C2
X212 / 1.0_2D.B2
D+ K2:16 16 21216 D+
D7971 / 1.0_2E1.C1
/0.0_2.C4 6
D+
/ 1.0_2B2.B2
/ 1.0_2C.C2
2107A
/ 1.0_2D.B2
582/7:1 7 582/7:1
/ 11.5_1.C8 / 1.0_2E2.B2
E / 1.0_2A.E2 E
/ 1.0_2B1.C1
/ 1.0_2C.D2
2108A
/ 1.0_2D.C2
582/8:1 8 582/8:1
/ 11.5_1.C8 / 1.0_2E1.C1
/ 1.0_2A.C2
X211 X278f / 1.0_2B1.D1
1.5A K1:32 32 21132 2 START
D7971 / 1.0_2E1.E1
/0.0_2.D5
B757
RELAY STARTING KEY XB757 XB757 X212
2102 7572 2 2 1 1 21215 15 K2:15 Reostat In
D7971
U /0.0_2.C4
F SENSOR FUEL LEVEL F
FUEL LEVEL
X37211A
X37211
Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets drivlina motor DCF300,DCE300 1.0_1
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 Ny konstruktion/New design 071520 TKB 071030 6
Wiring drive train engine A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
D5.2
X279
2791 1
A A
X279
2
X279
X37212 8
X279
9
X279
X210m 2103B 12
CAN_J1939_+ 3 2103A X90017
/ 1.0_1.C6 X279
2104B 13
/1.0_2A.F8
CAN_J1939_ 4 2104A X90018
/ 1.0_1.D6 X279
2108D 14
B D794 B
D+ 6 2106 ENGINE
/ 1.0_1.D6
X22
1 2108E
2 2798
3 2792
Diagnostics engine. 4 2104C
5 2799
6 2103C SWITCH CLOSES WHEN
C COOLANT LEVEL IS TOO LOW C
K315 B759
X278m 2 2 1 1
START 2 2782A 85 86 2782B
/ 1.0_1.F6 COOLANT LEVEL
GY
W224
87A 30 X37212
87
G660 BK
M654 B+
STARTING KEY
30 31 W225 B D+
M G
2
1
ALTERNATOR
D 50 D
X280m
STARTER W
secuted.
1
2
X280f
2105C
X210m
581/4:1 5 2105B
/ 1.0_1.D6
6
E E
20
K312
X23f
2108D 2108F 86 85 2108G 8 3
2108E X90016
582/8:1 8 2108B PREHEATER
/ 1.0_1.E6
/1.0_2A.B8
E800
W6 30 87 W7 1 2
PREHEATER D794
ENGINE
F D5.1 F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets motor TAD 722 DCF300,DCE300 1.0_2A
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring engine TAD722 A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
XD7941m
1/50
2/50
3/50
4/50
5/50
X210m XD7941f 6/50
581/3:1 1 2101 X90068 2101A 7 7/50
/ 1.0_1.C6
2101B 8 8/50
9/50
CAN_J1939_+ 3 30 2103 10/50
/ 1.0_1.C6
B 11/50 B
12/50
CAN_J1939_ 4 30 2104 13/50
/ 1.0_1.D6
14/50
15/50
581/4:1 5 2105 16/50
/ 1.0_1.D6
2101C 17 17/50
2105A 18 18/50
D+ 6 2106 X90069 19/50
/ 1.0_1.D6
20/50
21/50
582/8:1 8 2108 22/50
/ 1.0_1.E6
C 23/50 C
24/50
25/50
26/50
K360 27/50
X278m 2105B 28 28/50
START 2 2782 85 86 W19F W19A 29 29/50
/ 1.0_1.F6
W19B 30 30/50
87 30 31/50
87A 32/50
33/50
STARTING SOLENOID 34/50
D 35/50 D
36/50
secuted.
37 37/50
36030
38 38/50
W19C 39 39/50
RD W19D 40 40/50
41/50
42/50
G660 43/50
M654 B+
44/50
30 31 I W19
B 45/50
M G X90070 46 46/50
50 W 47/50
E E
48/50
WH 49/50
W19E 50 50/50
W11
D794 /1.0_2B2.D6
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets motor Cummins QSM11 DCF300,DCE300 1.0_2B1
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring engine Cummins QSM11 A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
SWITCH CLOSES WHEN
B B
COOLANT LEVEL IS TOO LOW
K322
X210m X759f X759m B759 X759m X759f X210m
582/7:1 7 2107 86 85 86 85 2102A 2 2 BK 2 2 1 1 GY 1 1 2102 2 CHASSIS
/ 1.0_1.E6 / 1.0_1.C6
/1.0_2B2.D3
XD7942f XD7942m
C W26 5 5/31 C
W25 6 6/31
K322 7 7/31
30 30 87
87A 87a W25A 19 19/31
/1.0_2B2.B3
COOLANT LEVEL
D794 /1.0_2B1.F6
D D
secuted.
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets motor Cummins QSM11 DCF300,DCE300 1.0_2B2
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring engine Cummins QSM11 A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
X22
1 221
2 2798
3 2793
Diagnostics engine. 4
5 2797
6
B B
X210m
581/3:1 1 2101
/ 1.0_1.C6
X279f X279m
CAN_J1939_+ 3 2103 30 2103 1 1/8
/ 1.0_1.C6
2104 2 2/8
C CAN_J1939_ 4 2104 2793 3 3/8 C
/ 1.0_1.D6
2101 4 4/8
D+ 6 2106
/ 1.0_1.D6
2795 5 5/8
582/7:1 7 2107 X90082 2107 6 6/8
/ 1.0_1.E6
2797 7 7/8
582/8:1 8 2108A 2798 8 8/8
/ 1.0_1.E6
D794
D D
Only 950 & 1250
secuted.
Volvos harness
XG660D+ W
E L E
1
15
65430 1
BS
DFM
M654
G660 G660
B+ 30 31
M
D+ B
G
50
ALTERNATOR STARTER
W
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets motor 950,1240,1250 DCF300,DCE300 1.0_2C
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 Connection 950,1250 changed 071520 TKB 071030 6
Wiring engine 950,1240,1250 A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
G660
B+
A 2106 D+ B A
G
ALTERNATOR
W
X210m
581/3:1 1 2101
/ 1.0_1.C6
CHASSIS 2 2102
/ 1.0_1.C6
X279f X279m
CAN_J1939_+ 3 2103 30 2103 1 1/8
/ 1.0_1.C6
2104 2 2/8
B CAN_J1939_ 4 2104 2102 3 3/8 B
/ 1.0_1.D6
2101 4 4/8
D+ 6 2106 2108 5 5/8
/ 1.0_1.D6
2107 6 6/8
582/7:1 7 2107 7/8
/ 1.0_1.E6
8/8
582/8:1 8 2108
/ 1.0_1.E6
X22A X22f X22m

1 221 1 1/6
2 222 30 2 2/6
C C
3 223 225 3 3/6
Diagnostics engine. 4/6
5 225 30 5 5/6
222 6/6
XK312Am XK312Af
1 1/2
2 2/2
D D
secuted.
K312 D794
XK312f XK312f
1 86 85 2
Volvo harness
XK31230 30 87 XK31287 UH
PRE HEAT
E8001 E8002
E 1 2 1 2 E
M654
Preheat cylinder Preheat cylinder
31 30 XM65430 31230
M
50
STARTER E8003 E8004
1 2 1 2
31287 XE800
E8005 E8006
1 2 1 2
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets motor TAD760 DCF300,DCE300 1.0_2D
CJS 051123 A47137.0100
Name
R
E³ DRAWING
1 Preheat added. 071520 TKB 071030 6
Wiring engine TAD760 A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
D794
F56
XD7943f XD7943m
A 7941 1 1/4 A
7942 2 2/4
65430-2 B:1 30A 2:1 7943 3 3/4
2:2 7944 4 4/4
XD7942m
1/50
2/50
3/50
4/50
B 5/50 B
F56 6/50
1 7/50
2 Power ECU D794
3 8/50
4 9/50
5 10/50
X37217
6
X210m 11/50
D+ 6 2106 12/50
/ 1.0_1.D6
13/50
582/8:1 8 2108 14/50
/ 1.0_1.E6
15/50
16/50
C 17/50 C
18/50
19/50
ALTERNATOR P 20/50
B WH 21/50
L
G B 22/50
B+ 23/50
G660 24/50
25/50
K312 26/50
F51 E800
65430-1 31230 30 87 31287 1 2 XD7942f 27/50
1 2
125A /1.0_2E1.E5 PREHEATER D79428 28 28/50
/ 1.0_2E2.D7
D RELAY PREHEATER 29/50 D
30/50
M654
secuted.
31/50
30 31 D79432 79432 32 32/50
M / 1.0_2E2.C2
RD 33/50
50 34/50
STARTER
35/50
36/50
K360 37/50
36030 30 87 36087 38/50
/1.0_2E1.E3 2108 39 39/50
RELAY STARTER 31286 40 40/50
E 41/50 E
K312 31285 42 42/50
86 85 43/50
K360 /1.0_2E1.D5 44/50
X278m
START 2 2782 86 85 W19 RELAY PREHEATER 45/50
/ 1.0_1.F6
/1.0_2E1.E3 30 46 46/50
RELAY STARTER 47 47/50
X37217 48/50
49/50
X210m 50/50
CAN_J1939_+ 3 2103 30
F / 1.0_1.C6 F
CAN_J1939_ 4 2104
/ 1.0_1.D6

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets motor QSB6,7 DCF300, DCE300 1.0_2E1
CJS 070123 A47137.0100
Name
R
E³ DRAWING
1 Cable WH was red now white. 071520 TKB 071030 6
Wiring engine QSB6,7 A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B SWITCH CLOSES WHEN B
COOLANT LEVEL IS TOO LOW
K322
X210m X759f B759 X759f X210m
582/7:1 7 2107 86 85 86 85 2102A 2 2 1 1 2102 2 CHASSIS
/ 1.0_1.E6 / 1.0_1.C6
D79432 79432 30 30 87 XR820f XR820m

/ 1.0_2E1.D7 R82010
87A 87a 322-87A A A 1 2
18,0kOHM
COOLANT LEVEL
C R82011 C
322-30 B B 1 2
560kOHM
C C
V
Coolant level OK = 0,5V2,1V
Coolant level low = 4,5V4,9V
79428 D79428
/ 1.0_2E1.D7
D D
secuted.
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets motor QSB6,7 DCF300, DCE300 1.0_2E2
CJS 070123 A47137.0100
Name
R
E³ DRAWING
1 XR820, 32230, 32287A added. 071520 TKB 071030 6
Wiring engine QSB6,7 A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
X017
S162 MULTISWITCH 12 K3:12 Input
D7902
/11.5_4.F4
/9.6_4.D4
GEAR SWITCH REVERSE
R R BK/WH/GN
X017
24V reference K3:10 10 RD 15/1 N N
D7902
/11.5_4.F4
X017
24V REF TO GEAR SWITCH F F BK/GN 11 K3:11 Input
D7902
/11.5_4.F4
GEAR /9.5_1.B4 GEAR SWITCH FORWARD
B B
X038f X038m S2201 X038m X038f X006

7901:51/24V 0811 0381A 1 1 BK 1 2 BN 2 2 0382A 00614 14 K6:14 Input
/ 9.1_1.C2 D7901
BU 3 /0.0_1.B4
DECLUTCHING PEDAL DECLUTCHING
XS2203f XS2203f
C 0381B 1 7901:51/24V 7901/6:14 2 0382B C
/ 9.3_3.F2 / 9.3_3.F6
S2202
P
X211
582/5:1 216-1B 1 2 21127 27 K1:27 Analog In 05V
/ 9.6_5.E2 D7971
582/5:1 216-1C /0.0_2.D5
/ 4.0_1.C2 DECLUTCHING
SWITCH DECLUTCHING
X205m
CAN_J1939_+ 30 2035 A CAN_J1939_+
D / 11.6_1.C2 / 2.0_2A1.B2 D
2036
secuted.
CAN_J1939_ 30 2036 B CAN_J1939_
/ 11.6_1.C2 / 2.0_2A1.B2
2035
X201f / 2.0_2A1.C7
2011 1 CHASSIS
/ 2.0_2B1.C7
2012
/ 2.0_2A1.C2
581/5:1 2 581/5:1
/ 11.5_1.C5 / 2.0_2B1.C2
E E
2013
/ 2.0_2A1.C7
3 CHASSIS
/ 2.0_2B1.C7
2014
/ 2.0_2A1.C2
582/6:1 4 582/6:1
X37211B / 11.5_1.B8 / 2.0_2B1.C2
X37211
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets drivlina växellåda DCF300,DCE300 2.0_1
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 Extra declutch, XS2203 added. 071520 TKB 071030 6
Wiring drive train gearbox A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
D793
CAN
X205f X252f
CAN_J1939_ B 252A2 A2 L2 ECU793
/ 2.0_1.D7 CAN L
CAN_J1939_+ A 252B2 B2 M2
/ 2.0_1.D7 CAN H
C
B B
251K3D 0V_ref
/ 2.0_2A2.E2
C C
D793
X201m X251f X251f X201m
581/5:1 2 251A1 A1 A1
ECU793 A3 A3 251A3 1 CHASSIS
/ 2.0_1.E7 PPWR Power Supply GND / 2.0_1.E7
X252f X252f
582/6:1 4 252F2 F2 S2 S3 F3 252F3B 252F3A 3 CHASSIS
/ 2.0_1.E7 SPWR VFSGND / 2.0_1.E7
D CHASSIS 252F3D D
/ 2.0_2A3.E7
secuted.
D793
RS 232
E ECU793 X252f X261m E
N2 C2 252C2 A
R x D
P2 D2 252D2 B
T x D
C
251K3E 0V_ref
/ 2.0_2A2.E2
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets växellåda TE32 DCF300,DCE300 2.0_2A1
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 Kabel 252F3C utgår. 071520 TKB 071030 6
Wiring gearbox TE32 A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
X251f
RPM B3 B3 251B3
D793
XB752
B752 1 1
A X251f A
2 2 251C3 C3 C3 RPM
D793
DRUM SPEED
X251f
RPM D3 D3 251D3
D793
XB758
B758 1 1 X251f
2 2 251E3 E3 E3 RPM
D793
OUTPUT SPEED
B B
B758/766
XB766 X251f
T T 1 251H3 H3 H3 Analogue Input
D793
2 251G3
+ 3 251F3 X251f
G3 G3 RPM
D793
ENGINE SPEED/GEARBOX TEMPERATURE
X251f
F3 F3 RPM
D793
S221
C XS221 C
251J3B X37Gearbox
1 T 2
TEMP SWITCH COOLER IN
(CONVERTER OUT TEMP)
X251f
251J3A J3 J3 Analogue Input
D793
X252f R8 R7
5V Analogue Ref M1 B1 252B1 1 2 251J3C 1 2
D793
10KOhm 10KOhm
251K3B
X252f
D RPM R2 E2 252E2 D
D793
X251f
K3 Signal GND
secuted.
XB751 K3
D793
B751 1 1
2 2 251K3C
TURBINE SPEED
0V_ref 251K3D 251K3A
/ 2.0_2A1.B7
0V_ref 251K3E
/ 2.0_2A1.E7
E B765
E
P PRESURE FEEDBACK SENSOR
X251f X253f X253f
Rheostat Input A2 A2 251A2 11 15 251K3F
D793
2K2
2K2
F F

Ruta Sign.
Sq.
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
Y6069
X251f X253f X253f X251f
Analogue Output D1 D1 251D1 1 1 2 2 251E1 E1 E1 Analogue Output
D793 D793
VFS 2ND/4TH
Y630
X251f X253f X253f X251f
Analogue Output B1 B1 251B1 3 1 2 4 251C1 C1 C1 Analogue Output
B D793 D793 B
VFS FWD
Y6067
X251f X253f X253f X251f
Analogue Output H1 H1 251H1 5 1 2 6 251J1 J1 J1 Analogue Output
D793 D793
VFS 1ST/3RD
C C
Y631
X251f X253f X253f X251f
Analogue Output F1 F1 251F1 7 1 2 8 251G1 G1 G1 Analogue Output
D793 D793
VFS REV
Y6066
X251f X253f X253f X251f
Digital Output K1 K1 251K1 9 1 2 10 251K2 K2 K2 Digital Output
D793 D793
D D
secuted.
DRIVE
Y6074
X251f X253f X253f
Digital Output E2 E2 251E2 12 1 2 14 252F3D CHASSIS
D793 / 2.0_2A1.D2
2/4 SELECT
Y6075
E X251f X253f E
Digital Output F2 F2 251F2 13 1 2
D793
1/3 SELECT
F F

Ruta Sign.
Sq.
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 Ventil Y602 utgår. 071520 TKB 071030 6
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
D793
CAN
X205f X252f
CAN_J1939_ B 30 252A2 30 A2 L2 ECU793
A / 1.0_1.D6 CAN L A
CAN_J1939_+ A 252B2 B2 M2
CAN H
B B
D793
C X201m X251f X251f X201m C
581/5:1 2 251A1 A1 A1
ECU793 A3 A3 251A3 1 CHASSIS
/ 2.0_1.E7 PPWR Power Supply GND / 2.0_1.E7
X201m X252f X252f X201m
582/6:1 4 252F2 F2 S2 S3 F3 252F3B 3 CHASSIS
/ 2.0_1.E7 SPWR VFSGND / 2.0_1.E7
0V_ref 252F3C
/ 2.0_2B2.F7
252F3A
0V_ref 252F3D
/ 2.0_2B3.E8
D D
D793
secuted.
RS 232
ECU793 X252f X261m
N2 C2 252C2 A
R x D
P2 D2 252D2 B
T x D
C
251K3D 0V_ref
/ 2.0_2B2.E1
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets växellåda TE17 DCF300, DCE300 2.0_2B1
CJS 061129 A47137.0100
Name
R
E³ DRAWING
1 New page 071520 TKB 071030 6
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
X251f
RPM B3 B3 251B3
D793
A XB752f A
DRUM SPEED B752 1 1 X251f
2 2 251C3 C3 C3 RPM
D793
DRUM SPEED
DRUM SPEED
X251f
RPM D3 D3 251D3
D793
XB758f
OUTPUT SPEED B758 1 1 X251f
2 2 251E3 E3 E3 RPM
D793
OUTPUT SPEED
OUTPUT SPEED
B B
X251f
251H3 H3 H3 Analogue Input
D793
GEARBOX TEMPERATURE
B758/766
XB766f
T T B X251f
C 251G3 G3 G3 RPM
D793
+ A
ENGINE SPEED/GEARBOX TEMPERATURE
C ENGINE SPEED/GEARBOX TEMPERATURE C
X251f
251F3 F3 F3 RPM
D793
S221
XS221
2211 1 2 T 1 ENGINE SPEED
X37GND_GEARBOX
TEMPERATURE SWITCH COOLER IN/CONVERTER OUT
X251f
251J3 J3 J3 Analogue Input
D793
X252f R8208 R8209
5V Analogue Ref M1 B1 252B1 1 2 1 2 251K3B TEMPERATURE SWITCH COOLER IN
D D793 D
10KOhm 10KOhm
TEMPERATURE SWITCH COOLER IN
secuted.
0.6W 0.6W
X252f
RPM R2 E2 252E2
D793
XB751f
TURBINE SPEED B751 1 1 X251f
2 2 251K3C 251K3A K3 K3 Signal GND
D793
TURBINE SPEED
0V_ref 251K3D
/ 2.0_2B1.E7
E E
B765
P PRESSURE FEEDBACK SENSOR
X251f X253f X253f
Rheostat Input A2 A2 251A2 11 1 2 12 252F3C 0V_ref
D793 / 2.0_2B1.D2
2K2
PRESSURE FEEDBACK SENSOR
1 2
F 2K2
F

Ruta Sign.
Sq.
CJS 061129 A47137.0100
Name
R
E³ DRAWING
1 New page 071520 TKB 071030 6
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A Y630 A
X251f X253f X253f X251f
Analogue Output B1 B1 251B1 3 1 2 4 251C1 C1 C1 Analogue Output
D793 D793
VFS FWD
Y6067
X251f X253f X253f X251f
Analogue Output H1 H1 251H1 5 1 2 6 251J1 J1 J1 Analogue Output
B D793 D793 B
VFS 1ST/3RD
Y1
X251f X253f X253f X251f
Analogue Output D1 D1 251D1 1 1 2 2 251E1 E1 E1 Analogue Output
D793 D793
C C
VFS 2ND
Y631
X251f X253f X253f X251f
Analogue Output F1 F1 251F1 7 1 2 8 251G1 G1 G1 Analogue Output
D793 D793
VFS REV
D D
secuted.
Y6066
X251f X253f X253f X251f
Digital Output K1 K1 251K1 9 1 2 10 251K2 K2 K2 Digital Output
D793 D793
DRIVE
E E
Y6075
X251f X253f X253f
Digital Output F2 F2 251F2 13 1 2 14 252F3D 0V_ref
D793 / 2.0_2B1.D2
1/3 SELECT
F F

Ruta Sign.
Sq.
CJS 061129 A47137.0100
Name
R
E³ DRAWING
1 New page 071520 TKB 071030 6
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
X008
+CAB 00813A 13 K8:13 Input
A S107 D7901 A
/0.0_1.D4
24V D7901/8:16 00816H 1
/ 7.5_3.B2 SWITCH PBRAKE LOCKED
0
1 1
24V D7901/8:16 00816J 5 5
/ 8.2_1.B2 7 7 0085
10 10 9 9
CHASSIS37D 0923F 00813B X008
/ 7.5_3.B2 PARKING BRAKE
5 K8:5 Input
D7901
/0.0_1.D4
SWITCH PBRAKE OPEN
B B
S200
P
X211
582/5:1 216-1C 1 2 21141 41 K1:41 Analog In 05V
/ 2.0_1.D2 D7971
/0.0_2.E5
PARKING BRAKE
PRESSURE SWITCH PBRAKE
C C
S204
P
X211
216-1D 1 2 21113 13 K1:13 Analog In 05V
D7971
/0.0_2.D2
PRESSURE ACCUMULATORTANK
PRESSURE SWITCH ACCU. TANK
D D
secuted.
Y642
E X211 E
1.5A K1:34 34 21134 1 1 2 2 642 CHASSIS
D7971 / 7.2_2.F5
/0.0_2.D5
VALVE PARKING BRAKE
PARKING BRAKE
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets Bromssystem DCF300,DCE300 4.0_1
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 X211.34 V X211.39. 071520 TKB 071030 6
Wiring brake system A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B772
XB772f XB772f X212
2 2 T 1 1 2126 6 K2:6 Temperature Input
D7971
U /0.0_2.B4
BRAKE OIL TEMPERATURE SENSOR BRAKE OIL TEMP.
B B
7722
K3774
X211
1.5A K1:3 3 2113 86 85 86 85 W212G CHASSIS
C D7971 / 11.5_3.D7 C
/0.0_2.D2
RELAY COOLING FAN BRAKE OIL
M674
XM674f XM674m XM674m XM674f
581/6:1 377430 30 30 87 87 6741 1 1 1 2 2 2 6742
/ 11.5_1.C5 M
87A
COOLING FAN BRAKE OIL X37202B
COOLING FAN BRAKE OIL
X37202
D Feedback oil cooler brakes D
secuted.
XM674Am XM674Af XM674Af XM674Am
1 674A1A 674A1B 1 2 674A2 2
X90101
XB771m
E 674A1C C 24V D7971/1:23 E
/ 7.7_2.C5
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets kyln. bromsl olja DCF300,DCE300 4.8_1
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 Feedback oil cooler added. 071520 TKB 071030 6
Wiring cooling brake oil A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
+CAB
S1492
1
0 XS1492m XS1492f X009Af X009Am X009
X009 X009Am X009Af XS1492f XS1492m 1 2 2 009910A 10 10 00910 10 K9:10 Input
A 24V reference K9:1 1 0091 1 1 0091A 1 1 5 D7901 A
D7901 /0.0_1.B6
/0.0_1.A6
HORN SWITCH HORN ARM REST
SWITCHES ARM REST
+CAB
S113
1
0 XS113m XS113f X009Af X009Am X009
XS113f XS113m 1 2 2 0095A 5 5 0095 5 K9:5 Input
0091B 1 1 5 D7901
/0.0_1.B6
SW ACT. MICRO STEERING
ACTIVATE LEVER / MICRO STEERING
B B
X009Af X009Am X009
0094A 4 4 0094 4 K9:4 Input
1 = FORWARD D7901
+CAB /0.0_1.B6
S1602 0 = NEUTRAL SW FORWARD ARM REST
1 2 = REVERSE
0
2
1 1 X009Af X009Am X009
0091C 3 3
7 7 0093A 3 3 0093 3 K9:3 Input
D7901
2 /0.0_1.B6
4
8 SW REVERSE ARM REST
X009 X009Am X009Af X009Af X009Am
1.5A K9:2 2 0092 2 2 0092A 10 10 9 9 W11A 11 11 W11
D7901
/0.0_1.A6
FORWARD / REVERSE
LAMP F/R ARM REST
C C
X37D
X825Hm
RD 1
X825Pm R8251 X825Pm

3
1 YE 1 2 GN 2
LEVER STEERING (P6)
X825Hm X825Hf X009Af X009Am X009
WH 1 1 0098A 8 8 0098 8 K9:8 Analog Input
D7901
/0.0_1.B6
POT. MICRO STEERING (P6)
D D
secuted.
X009 X009Am X009Af X825Pf X825Pm R8251 X825Pm X825Pf X009Af X009Am X009
Analog reference 5V 3 0V reference
K9:7 7 0097 7 7 0097A 1 1 GN 1 2 BN 2 2 0096A 6 6 0096 6 K9:6
D7901 D7901
/0.0_1.B6 /0.0_1.B6
POT. MICRO STEERING MICRO STEERING (P6) POT. MICRO STEERING
X825Hm X825Hf X009Af X009Am X009

R8252 YE 2 2 0099A 9 9 0099 9 K9:9 Analog Input
D7901
3 /0.0_1.B6
GY 1 2 BU
POT. MIC STEER/6TH LEV (P7)
MICRO STEERING (P7)
E E
X018 XB770f XB770m
1.5A K8:1 1 0181 1 1
D7902
/11.5_4.F4
SENSOR STEERING WHEEL
BN
B770 XB770m XB770f X018
BK 2 2 0182 2 K8:2 Input
D7902
/11.5_4.F4
STEERING WHEEL ANGLE
BU SENSOR STEERING WHEEL
F XB770m XB770f X018
3 3 0183 3 K8:3 0V ref F
D7902
SENSOR STEERING WHEEL

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets spak/miniratt styrning DCF300,DCE300 5.2_1
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring lever/micro wheel A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
Y6363
X221 X244f X244m X244m X244f X221
1.5A K1:2 2 2212 10 10 24410 1 1 2 2 24412B X90039 24412A 12 12 22116 16 K1:16 PWM
D7972 D7972
/0.0_3.C2 /0.0_3.D2
VALVE MICRO STEERING RIGHT VALVE MICRO STEERING
MICRO/LEVERSTEERING RIGHT
B B
Y6364
X221 X244f X244m
1.5A K1:3 3 2213 11 11 24411 1 1 2 2 24412C
D7972
/0.0_3.C2
VALVE MICRO STEERING LEFT
MICRO/LEVERSTEERING LEFT
C C
D D
secuted.
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets spak/miniratt styrning DCF300,DCE300 5.2_2
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring lever/micro wheel A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
XR8071m XR8071f X090m X090f X007

R8071 RD 0903 0073 Analog Input
3 3 3 3 3 K7:3
D7901
/0.0_1.C4
A POT. LIFT / LOWER (P1) A
X007 X090f X090m XR8071f XR8071m X090m X090f X007
Analog reference 5V 3 0V reference
K7:2 2 0072 2 2 0902A 1 1 GN 1 2 YE 2 2 0901A 1 1 0071 1 K7:1
D7901 D7901
/0.0_1.C4 /0.0_1.B4
POTENTIOM. EL. SERVO LIFT / LOWER (P1) POTENTIOM. EL. SERVO
0902B
0901B
XR8072m XR8072f X090m X090f X007
3 3 4 4 4 K7:4
D7901
/0.0_1.C4
POT. TILT (P2)
B XR8072f XR8072m B
3
1 1 GN 1 2 YE 2 2
TILT (P2)
Placering spakar från vänster
Placement levers from left
0902C
0901C
P1 XR8073m XR8073f X090m X090f X007
P2 3 3 5 5 5 K7:5
D7901
/0.0_1.C4
P3 POT. SIDE SHIFTING (P3)
XR8073f XR8073m
P4 3
C 1 1 GN 1 2 YE 2 2 C
P7 opt. FCH
SIDE SHIFTING (P3)
P5
0902D
0901D
XR8074m XR8074f X090m X090f X007
3 3 6 6 6 K7:6
D7901
/0.0_1.C4
POT. SPREADING (P4)
XR8074f XR8074m
3
1 1 GN 1 2 YE 2 2
D D
SPREADING (P4)
PROJECTION LEFT
secuted.
0902E
0901E
XR80751m XR80751f X090m X090f X007

3 3 7 7 7 K7:7
D7901
/0.0_1.C4
POT. EXTRA (P5)
XR80751f XR80751m
3
1 1 GN 1 2 YE 2 2
EXTRA (P5)
E E
LEVELLING
0902F
0901F
XR80752m XR80752f X090m X090f X009

3 3 8 8 9 K9:9
D7901
POT 7TH LEVER (P7)
XR80752f XR80752m
3
1 1 GN 1 2 YE 2 2
F EXTRA (P7) F
PROJECTION RIGHT

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets elservo spakar DCF300,DCE300 7.0_1
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring el. servo levers A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
Lever 815
X007 X091f X091m X815f T11 X815f X091m X091f X007f
Analog Reference 24V K7:12 12 00712 8 8 0918 15 15 14 14 0913 3 3 00714 14 K7:14 Input
D7901 D7901
/0.0_1.C4
SWITCHES EL. SERVO SW. SPREAD IN
T12 X091m X091f X007f
16 16 0914 4 4 00713 13 K7:13 Input
B D7901 B
SW. SPREAD OUT
T2 X091m X091f X007f
20 20 0915 5 5 00715 15 K7:15 Input
D7901
SWITCH UNLOCK TW
T4 X091m X091f X007
19 19 0916 6 6 00716 16 K7:16 Input
D7901
/0.0_1.C4
SWITCH PISTOL
T31 X091m X091f X008
17 17 0919 9 9 0081 1 K8:1 Input
X007 X091f X091m D7901
0.5A K7:9 9 0079 7 7 0917 7 7
D7901
/0.0_1.C4 SWITCH LOCK LEVELLING
IND. LOCKED LEVELLING
C T32 X091m X091f X008 C
18 18 0912 2 2 0082 2 K8:2 Input
D7901
CHASSIS37D 0923H 5 /0.0_1.D4
/ 7.8_1.F7
SWITCH LOCK TILT
6 6
X090m X090f X007f
P1 8 8 0903 3 3 0073 3 K7:3 Analog Input
X007f X090f X090m D7901
Analog Reference 5V K7:2 2 0072 2 2 0902 9 9
D7901
POT. LIFT / LOWER (P1)
POTENTIOM. EL. SERVO
X090m X090f X007f
P2 4 4 0904 4 4 0074 4 K7:4 Analog Input
D7901
POT. TILT (P2)
D X090m X090f X007f D

P3 11 11 0905 5 5 0075 5 K7:5 Analog Input
D7901
secuted.
POT. (P3)
X090m X090f X007f

P4 1 1 0906 6 6 0076 6 K7:6 Analog Input
D7901
X007f X090f X090m
0V Reference K7:1 1 0071 1 1 0901 10 10 POT. (P4)
D7901
POTENTIOM. EL. SERVO
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets elservo joystick DCF300,DCE300 7.0_2
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 X007.9 skiftad med X007.12 071520 TKB 071030 6
Wiring el. servo joystick A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
2028 583/3:1
/ 7.0_5.D2
X207m X207f
B 2075 5 5 2025 Alignment B
/ 7.0_5.E2
X207f X207m R8203 X207m X207f X070m X070f X010

1 1 1 2 2 2 0701 1 1 A0103 3 K10:3 Input
D7901
/0.0_1.B6
820 Ohm
SENSOR ALIGNMENT
X207m X207f
C 2076 6 6 2026 Unlock TW C
/ 7.0_5.E2
R8204 X207m X207f X070m X070f X069f X069m X008

3 3 0702 2 2 A0692 2 2 0089 9 K8:9 Input
D7901
/0.0_1.D4
820 Ohm
SENSOR UNLOCK TW
X207m X207f
D 2077 7 7 2027 Lock TW D
/ 7.0_5.F2
secuted.
R8205 X207m X207f X070m X070f X069f X069m X008
4 4 0703 3 3 A0693 3 3 0088 8 K8:8 Input
D7901
/0.0_1.D4
820 Ohm
SENSOR LOCK TW
E E
X081f
0053B 3
X005 X040m X040f X040f X040m X005

PWM (NPN) K5:3 3 0053A 1 1 A0401 6 6 00514 14 K5:14 Input (K10:3)
D7901 D7901
/0.0_1.C1 /0.0_1.D1
OVERRIDE ALIGNMENT OVERRIDE ALIGNMENT
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets tillbehörsaggregat DCF300,DCE300 7.0_4
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 Flyttad från 9.1_3 071520 TKB 071030 6
Wiring toplift frame A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
K3005
X007 X069m X069f
0.5A K7:10 10 00710 4 4 A0694A 86 85 A0694B
D7901
/0.0_1.C4
RELAY ACTIVATE TW X070f X070m X202f X202m X208f X208m X208Am
A0707C 30 87 A0706 6 6 0706 1 1 BN_/_1 1 1 BN_/_1 1
VALVE TWISTLOCK
TWISTLOCK
584/5:2
/ 11.5_2.B6
B B
A0707B
K3006
X007 X069m X069f
0.5A K7:11 11 00711 5 5 A0695A 86 85 A0695B
D7901
/0.0_1.C4
RELAY ACTIVATE SPREAD X070f X070m X202f X202m X208f X208m X208Am
30 87 A0707A 7 7 0707 2 2 RD_/_2 2 2 RD_/_2 2
VALVE SPREADING
SPREADING
X37A
C C
X202f X202m X208f X208m X208Am

CHASSIS 2023 3 3 OG_/_3 3 3 OG_/_3 3
/ 9.7_2.C7 CHASSIS
D X202f X202m X208f X208m X208Am D

583/3:1 2024 4 4 YE_/_4 4 4 YE_/_4 4
/ 11.5_6.D7 24V
secuted.
583/3:1 2028 8 8 GY_/_8 13 13 4A
/ 7.0_4.A7
X202f X202m X208f X208m X208Am

Alignment 2025 5 5 GN_/_5 5 5 GN_/_5 5
/ 7.0_4.B7 SENSOR ALIGNMENT
Se krets aggregat
See circuit attachment
E X202f X202m X208f X208m X208Am E

Unlock TW 2026 6 6 BU_/_6 6 6 BU_/_6 6
/ 7.0_4.C7 SENSOR UNLOCK TWISTLOCK
X202f X202m X208f X208m X208Am

Lock TW 2027 7 7 VT_/_7 7 7 VT_/_7 7
/ 7.0_4.D7 SENSOR LOCK TWISTLOCK
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets tillbehörsaggregat DCF300,DCE300 7.0_5
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring toplift frame A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
C C
X302f X302m XB72111f XB72111m
582/5:1 2481C A A 302A A A
/ 7.2_6.E1
BN
B72111 XB72111m XB72111f X302m X302f X248m X248f X211
BK C C 302C C C 2484 4 4 21126 26 K1:26 Dig In / 1.5A
D7971
/0.0_2.D5
AUT. CAB TILT
BU SENSOR CAB TILT
B B 302B B B 2482C CHASSIS

/ 7.2_6.F7
D D
secuted.
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets lyfthöjd DCF300,DCE300 7.0_7
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring lift height A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
Y6005
X211 XK3007 K3007 XK3007 X235f X235m X235m X235f X211
1.5A K1:4 4 2114A 30 30 87 87 2114B 1 1 2351A X90029 2351B 1 1 2 2 2352 2 2 21116 16 K1:16 PWM
D7971 D7971
/0.0_2.D2 87A /0.0_2.D2
VALVE LIFT / LOWER /11.5_6.B4 VALVE LIFT / BLOCK LIFT
LIFT
C C
Y6004
X235m X235f X211
2351C 1 1 2 2 2353 3 3 21117 17 K1:17 PWM
D D7971 D
/0.0_2.D2
VALVE LOWER / BLOCK LOWER
secuted.
LOWER
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets lyft/sänk elservo DCF300,DCE300 7.2_1
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 Moved from 7.2_5 071520 TKB 071030 6
Wiring lift/lower el. servo A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
/ 7.2_3.C6 X236Lf X211

24V D7971/1:12 C 21112 12 K1:12 Dig In / 1.5A
/ 7.2_6.B1 D7971
/0.0_2.D2
CARRIAGE UP / REGENERATING LIFT
B X236Lf / 7.2_3.C6 X236Lf B

90012B A 582/5:2 CHASSIS B 237B
/ 7.2_3.B3 / 7.2_6.B7
582/5:2 90012A X90012

/ 11.5_1.B8
/ 7.2_3.D6 X236Rf X211

24V D7971/1:11 C 21111 11 K1:11 Dig In / 1.5A
/ 7.2_6.D1 D7971
/0.0_2.D2
MAST DOWN / REGENERATING LIFT
C C
X236Rf / 7.2_3.D6 X236Rf

90012C A 582/5:2 CHASSIS B 236B
/ 7.2_3.C3 / 7.2_6.D7
CHASSIS 6012
/ 10.4_1.D5
D D
secuted.
CHASSIS 771B
/ 7.7_2.D7
CHASSIS 6062 X90032 37209 CHASSIS

/ 10.4_1.C7 / 11.5_1.D6
CHASSIS 2482
/ 7.2_6.E7
E E
CHASSIS 2132
/ 9.0_1.C7
CHASSIS 6039
/ 8.2_3.D7
XY6040/6019f
2 6040
CHASSIS 642
F / 4.0_1.E7 F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets frilyft sensorer DCF300,DCE300 7.2_2
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring free lift sensors A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B X236Lm B
582/5:2 A RD XB260 1
/ 7.2_2.B3
BN
B260 X236Lm
BK XB260 2 GY C 24V D7971/1:12
/ 7.2_2.B5
SENSOR CARRIAGE UP
BU
X236Lm
XB260 3 BK B CHASSIS
/ 7.2_2.B5
C C
X236Rm
582/5:2 A
/ 7.2_2.C3
BN
B261 X236Rm
BK C 24V D7971/1:11
/ 7.2_2.C5
SENSOR MAST DOWN
BU
D D
X236Rm
secuted.
B CHASSIS
/ 7.2_2.C5
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets frilyft sensorer DCF300,DCE300 7.2_3
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring free lift sensors A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
Y6052
X236Lm X236Lm
B 24V D7971/1:12 C 236C 1 1 2 2 236B B CHASSIS B
/ 7.2_2.B5 / 7.2_2.B5
REGENERATING LEFT
C C
Y6051
X236Rm X236Rm
24V D7971/1:11 C 236C 1 1 2 2 236B B CHASSIS
/ 7.2_2.C5 / 7.2_2.C5
REGENERATING RIGHT
D D
secuted.
X248f X248m X301f X301m XB72112f XB72112m
582/5:1 2481 1 1 2481A 2481B A A 301A A A
/ 9.6_5.E2
X90076
BN
B72112 XB72112m XB72112f X301m X301f X248m X248f X211
BK C C 301C C C 2483 3 3 21124 24 K1:24 Analog In 05V
E D7971 E
/0.0_2.D5
MAST POSITION/STOP REGENERATING
582/5:1 2481C BU SENSOR MAST POS/REGENERATING
/ 7.0_7.C2
B B 301B B B 2482B 2482A 2 2 2482 CHASSIS
/ 7.2_2.E5
X90075
2482C CHASSIS
/ 7.0_7.D7
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets ventiler stativ DCF300,DCE300 7.2_6
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring control valves mast A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
Y60461
X421 XY60461 XY60461 X421
1.5A K1:2 2 4212 1 1 2 2 42116B 42116A 16 K1:16 PWM
D791 D791
/0.0_4.C2 X90050 /0.0_4.D2
PROJECTING LEFT IN PROJECTING LEFT
PROJECTING LEFT IN
B B
Y60462
X421 XY60462 XY60462
1.5A K1:3 3 4213 1 1 2 2 42116C
D791
/0.0_4.C2
PROJECTING LEFT OUT
PROJECTING LEFT OUT
C C
Y60463
X421 XY60463 XY60463 X421
1.5A K1:4 4 4214 1 1 2 2 42117B 42117A 17 K1:17 PWM
D791 D791
/0.0_4.C2 X90051 /0.0_4.D2
PROJECTING RIGHT IN PROJECTING RIGHT
PROJECTING RIGHT IN
Y60464
D X421 XY60464 XY60464 D
1.5A K1:5 5 4215 1 1 2 2 42117C
D791
/0.0_4.C2
secuted.
PROJECTING RIGHT OUT
PROJECTING RIGHT OUT
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets aggregat gantry DCF300,DCE300 7.3_1
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring projection gantry A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
Y6020
X221 X244f X244m X244m X244f X221
2.5A K1:31 31 22131 1 1 2441 1 1 2 2 2443B X90036 2443A 3 3 22118 18 K1:18 PWM
D7972 D7972
/0.0_3.D5 /0.0_3.D2
VALVE SIDESHIFT LEFT VALVE SIDESHIFT
B B
SIDESHIFT LEFT
Y6021
X221 X244f X244m
2.5A K1:30 30 22130 2 2 2442 1 1 2 2 2443C
D7972
/0.0_3.D5
VALVE SIDESHIFT RIGHT
SIDESHIFT RIGHT
C C
D D
secuted.
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets Sidoföring elservo DCF300,DCE300 7.4_1
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring Sideshift el. servo A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
Y6020
X421 X421
1.5A K1:32 32 42132 1 1 2 2 42118B 42118A 18 K1:18 PWM
D791 D791
/0.0_4.D5 X90052 /0.0_4.D2
VALVE SIDESHIFT LEFT VALVE SIDESHIFT
SIDESHIFT LEFT
B B
Y6021
X421
1.5A K1:33 33 42133 1 1 2 2 42118C
D791
/0.0_4.D5
VALVE SIDESHIFT RIGHT
SIDESHIFT RIGHT
C C
D D
secuted.
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets sidoföring gantry DCF300,DCE300 7.4_2
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring sideshift gantry A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A 1 = 40'20' A
0 = 0
2 = 20'40' X091m X091f X007
0913 3 3 00714 14 K7:14 Input
+CAB D7901
S1012 /0.0_1.C4
1 SWITCH SPREADING 4020
0
24V D7901/8:16 0921C 2
/ 9.7_4.B2 1 1 X091m X091f X007
24V D7901/8:16 0921D 3 3
/ 7.8_1.E2 7 7 0914 4 4 00713 13 K7:13 Input
D7901
2 /0.0_1.C4
4
8 SWITCH SPREADING 2040
CHASSIS37D 0923F 10 10 9 9
/ 7.9_1.B3
B CHASSIS37D 0923G B
/ 7.8_1.F2 2040
0922B 24V D7901/8:15
/ 7.8_1.E7
/ 9.3_3.B7 0922A
24V D7901/8:15
/ 9.10_1.B7
C C
+CAB
S1004
1 X008
00810A 10 K8:10 Input
24V D7901/8:16 00816D 0 D7901
/ 7.9_1.A2 1 1 /0.0_1.D4
24V D7901/8:16 00816E 5 5
/ 9.1_1.A2 7 SWITCH 3035 STOP
CHASSIS37D 0923B 10 10 9 9 00810B
/ 7.9_1.A2
CHASSIS37D 0923C
/ 9.1_1.A2 3035 STOP
D D
secuted.
Y6018
X221 X244f X244m X244m X244f X221
1.5A K1:33 33 22133 4 4 2444 1 1 2 2 2446B X90037 2446A 6 6 22119 19 K1:19 PWM
D7972 D7972
/0.0_3.D5 /0.0_3.D2
VALVE SPREADING OUT VALVE SPREADING
SPREADING OUT
E E
Y6019
X221 X244f X244m
1.5A K1:32 32 22132 5 5 2445 1 1 2 2 2446C
D7972
/0.0_3.D5
VALVE SPREADING IN
SPREADING IN
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets 2040, 3035 stopp DCF300,DCE300 7.5_1
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring 2040, 3035 stop A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
Y6018
X421 XY6018 XY6018 X421
1.5A K1:34 34 42134 1 1 2 2 42119B 42119A 19 K1:19 PWM
D791 D791
/0.0_4.D5 X90053 /0.0_4.D2
B B
VALVE SPREADING OUT VALVE SPREADING
SPREADING OUT
Y6019
X421 XY6019 XY6019
1.5A K1:35 35 42135 1 1 2 2 42119C
D791
/0.0_4.D5
VALVE SPREADING IN
C C
SPREADING IN
XB7691f XB7691m
24V D7911/1:10 4041C A A
/ 7.9_2.F3
BN
B7691 XB7691m XB7691f X404Am X404Af X421
BK C C 4047 7 7 42112 12 K1:12 Dig In / 1.5A
D791
/0.0_4.D2
DAMPING 2040
BU SENSOR DAMPING 2040
D XB7691m XB7691f D
B B 4042C CHASSIS
/ 7.9_2.F4
secuted.
XB7771f XB7771m
24V D7911/1:10 4041D A A
/ 7.9_2.F3
BN
B7771 XB7771m XB7771f X404Am X404Af X421
BK C C 4048 8 8 42120 20 K1:20 Analog In 05V
D791
/0.0_4.D2
3035 STOP
BU SENSOR 3035 STOP
XB7771m XB7771f
E B B 4042D CHASSIS E
/ 7.9_2.F4
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets spridning gantry DCF300,DCE300 7.5_2
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring spreading gantry A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
S10122
/ 9.3_3.A2 1 X008
24V D7901/8:16 00816G 00811A 11 K8:11 Input
/ 9.10_1.A2 0 D7901
1 1 /0.0_1.D4
24V D7901/8:16 00816H 5 5
/ 4.0_1.A2 SWITCH AUT. 2040
CHASSIS37D 0923F 10 10 9 9 00811B
/ 4.0_1.B2
B / 9.3_3.B2 AUT. 2040 B
CHASSIS37D 0923E
/ 9.10_1.B2
C C
X421 XH9003f XH9003m H9003

6A K1:28 28 42128 1 1 RD +
D791
/0.0_4.D5 2 2 BK
D D
WARN. SIGNAL AUT. SPREADING
WARNING SIGNAL AUT. SPREADING
secuted.
W9003 CHASSIS
/ 9.6_2.F8
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets 2040 opt. DCF300,DCE300 7.5_3
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 Searchlight changed, 0811B T. 071520 TKB 071030 6
Wiring 2040 opt. A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
Y6010
X211 XK3002 K3002 XK3002 X235f X235m X235m X235f X211
1.5A K1:5 5 2115A 30 30 87 87 2115B 4 4 2354A X90030 2354B 1 1 2 2 2355 5 5 21119 19 K1:19 PWM
D7971 D7971
/0.0_2.D2 87A /0.0_2.E2
VALVE TILT /11.5_6.B4 VALVE TILT OUT
C C
TILT OUT
D D
secuted.
Y6011
X235m X235f X211
2354C 1 1 2 2 2356 6 6 21118 18 K1:18 PWM
D7971
/0.0_2.D2
VALVE TILT IN
TILT IN
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets tilt elservo DCF300,DCE300 7.7_1
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 Moved from 7.2_5 071520 TKB 071030 6
Wiring tilt el. servo A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
24V D7971/1:23
/ 4.8_1.E6
C C
XB771f XB771m
582/5:1 771A A A
/ 9.6_5.E2
BN
B771 XB771m XB771f X211
BK C C 21123 23 K1:23 Analog In 05V
D7971
/0.0_2.D5
SENSOR TILT ANGLE
BU SENS.TILT ANGLE/FEEDBACK BRK FAN
B B 771B CHASSIS
/ 7.2_2.D5
D D
secuted.
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets tiltindikering DCF300,DCE300 7.7_2
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring tilt indicator A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
Y6035
X421
2.5A K1:31 31 42131 1 1 2 2 6035 CHASSIS
A D791 / 7.9_1.E7 A
/0.0_4.D5
VALVE LEVELLING RIGHT
LEVELLING RIGHT
Y6036
B X421 B
2.5A K1:30 30 42130 1 1 2 2 6036 CHASSIS
D791 / 7.9_1.E7
/0.0_4.D5
VALVE LEVELLING LEFT
LEVELLING LEFT
C Y6371 C
X421
6A K1:42 42 42142A X90071 42142B 1 1 2 2 637-1 CHASSIS
D791 / 7.9_1.E7
/0.0_4.D5
VALVE UNLOCK LEVELLING
UNLOCK LEVELLING
D D
Y6372
secuted.
42142C 1 1 2 2 637-2 CHASSIS
/ 7.9_1.E7
UNLOCK LEVELLING
S1037
E 1 X091m X091f X008 E
0919A 9 9 0081 1 K8:1 Input
0 D7901
1 1 /0.0_1.D4
24V D7901/8:16 0921D 5 5
/ 7.5_1.B2 7 SWITCH LOCK LEVELLING
2 2 0919B
6 6
8 8 0922B 24V D7901/8:15
/ 7.5_1.B7
CHASSIS37D 0923G 10 10 9 9
/ 7.5_1.B2
LOCK LEVELLING
0922C
F 0923H CHASSIS37D
F
/ 7.0_2.C2

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets skevning gantry DCF300,DCE300 7.8_1
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring levelling gantry A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
+CAB
S1003
1
A 24V D7901/8:16 00816D 0 A
/ 7.5_1.C2 2
1
00816C 3 3
7 7 00812B
2 2 X008
4 4 00812A 12 K8:12 Input
8 D7901
/0.0_1.D4
CHASSIS37D 0923B 10 10 9 9 00812C
/ 7.5_1.D2 SWITCH LOCK TW
0923A
Twistlock
X092f X092m
0923 3 3 0923F
Vid hydr. servo
CHASSIS37D S1002 When hyd. servo
/ 7.5_1.B2
B X37D XS1002m2 XS1002m1 B
1 RD 2 1 BK 1
24V D7901/8:16 0921B
/ 9.7_4.B2 UNLOCK TW
00816B S1002
1
0
2 XS1002m3 XS1002f3 0915A
X008 X092f X092m XS1002f2 XS1002m2 3 X091m X091f X007
24V reference K8:16 16 00816A 1 1 0921A 2 0915 5 5 00715 15 K7:15 Input
D7901 1 D7901
/0.0_1.E4 /0.0_1.C4
SWITCH ELSERVO PANEL SWITCH UNLOCK TW
UNLOCK TW
C C
H562
X421 X405f X405m XH5621 XH5622
1.5A K1:25 25 42125 1 1 4051 1 1 2 1
D791
/0.0_4.C5
LAMP UNLOCKED TW UNLOCKED TW
H564
X421 X405f X405m XH5641 XH5642
1.5A K1:39 39 42139 2 2 4052 1 1 2 1 4054C
D791
/0.0_4.D5
LAMP ALIGNMENT ALIGNMENT
D D
H563
X421 X405f X405m XH5631 XH5632
1.5A
secuted.
K1:29 29 42129 3 3 4053 1 1 2 1 4054B
D791
/0.0_4.D5
LAMP LOCKED TW LOCKED TW
X405m X405f
4054A 4 4 4054 CHASSIS
/ 9.6_2.C8
6035 CHASSIS
/ 7.8_1.A7
Y6040 6036
X421 CHASSIS
/ 7.8_1.B7
1.5A K1:7 7 4217 1 1 2 2 6040
D791
/0.0_4.D2 637-1 CHASSIS
E / 7.8_1.C7 E
VALVE LOCK TWISTLOCK
LOCK TW 637-2 CHASSIS
/ 7.8_1.D7
Y6039
X421
1.5A K1:9 9 4219 1 1 2 2 6039 W402 CHASSIS
D791 / 11.5_5.B7
/0.0_4.D2 X90060
VALVE UNLOCK TWISTLOCK
F UNLOCK TW F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets Twistlock DCF300,DCE300 7.9_1
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 Connection S1002 changed. 071520 TKB 071030 6
Wiring twistlock A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
X403Am X403Af X403Bf X403Bm XB7202Rf XB7202Rm

1 1 4031 1 1 4031 X90054 4031A A A X403Bm X403Bf X403Af X403Am X421
A 4033 3 3 4033 3 3 42140 40 K1:40 Dig In / 1.5A A
BN D791
B7202R XB7202Rm XB7202Rf /0.0_4.D5
BK C C
SENSOR ALIGNMENT FRONT RIGHT
B B 4032A 4032 2 2 4032 2 2 4032
ALIGNMENT FRONT RIGHT
BU X90055
XB7204Rf XB7204Rm
4031B A A
BN
B7204R XB7204Rm XB7204Rf
BK C C 4032B X403Bm X403Bf X403Af X403Am X421
B B 4034 4 4 4034 4 4 42141 41 K1:41 Analog In 05V
UNLOCKED TWISTLOCK RIGHT D791
BU /0.0_4.D5
SENSOR UNLOCKED TW. RIGHT
XB7205Rf XB7205Rm
B 4031C A A B
BN
BK C C 4032C X403Bm X403Bf X403Af X403Am X421
B B 4035 5 5 4035 5 5 42124 24 K1:24 Analog In 05V
LOCKED TWISTLOCK RIGHT D791
BU /0.0_4.C5
SENSOR LOCKED TW. RIGHT
XB7203Rf XB7203Rm
4031D A A
BN
42110B BK C C 4032D X403Bm X403Bf X403Af X403Am X421
B B 4036 6 6 4036 6 6 42126 26 K1:26 Dig In / 1.5A
ALIGNMENT REAR RIGHT D791
BU /0.0_4.C5
SENSOR ALIGNMENT REAR RIGHT
C X421 42110C 24V D7911/1:10 C

/ 7.10_2.E2
1.5A K1:10 10 42110A X90058 769B CHASSIS
D791 / 7.10_2.F7
/0.0_4.D2 42110D 24V D7911/1:10 7211B CHASSIS
/ 7.10_2.A2 / 7.10_2.A7
SENSORS ATTACHMENT CHASSIS W401 X90059 4032
X404Am X404Af / 11.5_5.B7
4041A 1 1 42110E 4042
X404Bf X404Bm XB7202Lf XB7202Lm

X90083 4041B 1 1 4041 X90056 4041A A A X404Bm X404Bf X404Am X404Af X421
4043 3 3 4043 3 3 42113 13 K1:13 Analog In 05V
BN D791
B7202L XB7202Lm XB7202Lf /0.0_4.D2
BK C C
SENSOR ALIGNMENT FRONT LEFT
B B 4042A 4042 2 2 4042B 4042A 2 2 4042
ALIGNMENT FRONT LEFT
BU X90057 X90084
D XB7204Lf XB7204Lm D
4041B A A
BN
secuted.
B7204L XB7204Lm XB7204Lf
BK C C 4042B X404Bm X404Bf X404Am X404Af X421
B B 4044 4 4 4044 4 4 42122 22 K1:22 Analog In 05V
UNLOCKED TWISTLOCK LEFT D791
BU /0.0_4.C5
SENSOR UNLOCKED TW. LEFT
XB7205Lf XB7205Lm
4041C A A
BN
BK C C 4042C X404Bm X404Bf X404Am X404Af X421
B B 4045 5 5 4045 5 5 42123 23 K1:23 Analog In 05V
LOCKED TWISTLOCK LEFT D791
BU /0.0_4.C5
SENSOR LOCKED TW. LEFT
E XB7203Lf XB7203Lm E
4041D A A
BN
BK C C 4042D X404Bm X404Bf X404Am X404Af X421
B B 4046 6 6 4046 6 6 42127 27 K1:27 Analog In 05V
ALIGNMENT REAR LEFT D791
BU /0.0_4.D5
SENSOR ALIGNMENT REAR LEFT
4041C 24V D7911/1:10 CHASSIS 4042C
/ 7.5_2.D1 / 7.5_2.D6
4041D 24V D7911/1:10 CHASSIS 4042D
F / 7.5_2.D1 / 7.5_2.E6 F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets givare gantry DCF300,DCE300 7.9_2
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 Kabelnr, 2 splicar T. 071520 TKB 071030 6
Wiring sensors gantry A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
X242m
582/4:1 7 YE_/_4
/ 11.5_10.B4
X208Am X208Af X242m

A 1 1 BN_/_1 1 D7972/1:41 A
/ 11.5_10.A5
2 2
3 3 OG_/_3 8 CHASSIS
/ 11.5_10.D5
Strömbrytare S1008 klämma / lossa.
Kopplas in på XS1012. 4 4 YE_/_4
5 5
Switch S1008 clamping / releasing. 6 6 BU_/_6 3 D7972/1:22
/ 11.5_10.B5
Connected to XS1012.
7 7 VT_/_7 4 D7972/1:23
/ 11.5_10.C5
+CAB
S1008
B 1 B
0
2
1
3
7
2
4
8 K37681
10 9 86 86 85 85
CLAMPING RELEASING
30 30 87 87
87A
C C
K37682
86 86 85 85
30 30 87 87
87A 87a
D D
B7681
secuted.
1
2
3
4
OPENS AT 150 BAR
CLOSES AT 135 BAR
H50001
B7682
E 1 2 E
PRESSURE CYLINDER UNDER 125 BAR (RED) 1
2
3
4
H50002
1 2
OPENS AT 150 BAR
PRESSURE CYLINDER OVER 125 BAR (GREEN) CLOSES AT 135 BAR
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets tång Avesta DCF300,DCE300 7.9_3
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 Connection attachment Avesta changed. 071520 TKB 071030 6
Wiring attachment Avesta A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
Y6022
X221 X244f X244m X244m X244f X221
1.5A K1:4 4 2214 7 7 2447 1 1 2 2 2449B X90038 2449A 9 9 22117 17 K1:17 PWM
D7972 D7972
/0.0_3.C2 /0.0_3.D2
VALVE EXTRA FUNCT. OUT VALVE EXTRA FUNCT.
5TH FUNCTION OUT
C C
Y6023
X221 X244f X244m
1.5A K1:5 5 2215 8 8 2448 1 1 2 2 2449C
D7972
/0.0_3.C2
VALVE EXTRA FUNCT. IN
5TH FUNCTION IN
D D
secuted.
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets 5:e funkt. elservo DCF300,DCE300 7.10_1
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring 5th function el. servo A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
X409f X409f
24V D7911/1:10 42110D 1 24V D7911/1:10 CHASSIS 2 7211B CHASSIS
/ 7.9_2.C4 / 7.9_2.C7
X409f X421
24V D7911/1:21 3 42121 21 K1:21 Analog In 05V
X421 X409f D791
Analog Ref 5V K1:8 8 4218 5 /0.0_4.C5
B D791 B
/0.0_4.D2 OPT.
OPT.
X421 X409f X409f X421

1.5A K1:36 36 42136 7 4 4216 6 K1:6 0V Ref
D791 D791
/0.0_4.D5 /0.0_4.C2
OPT. OPT.
C C
X421 X409f
1.5A K1:37 37 42137 8
D791
/0.0_4.D5
OPT.
D D
secuted.
XB7692f XB7692f X421
24V D7911/1:10 42110C A C 42111 11 K1:11 Dig In / 1.5A
E / 7.9_2.C4 D791 E
/0.0_4.D2
SENSOR OPT.
B 769B CHASSIS
/ 7.9_2.C7
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets option gantry DCF300,DCE300 7.10_2
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 X409.6 utgår. 071520 TKB 071030 6
Wiring option gantry A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
+CAB
B S1005 B
1
0 XS1005 X008
XS1005 1 1 0083 3 K8:3 Input
24V D7901/8:16 00816J 5 5 D7901
/ 4.0_1.A2 /0.0_1.D4
24V D7901/8:16 00816K
/ 11.5_6.A2 OVER RIDE SWITCH OVERRIDE
C C
D D
secuted.
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets förbikoppling DCF300,DCE300 8.2_1
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring override A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
X211 X7681f X7681m B7681 X7681m X7681f

Analog Ref 5V K1:8 8 2118A X90031 2118B A A 768-1A 1 2 768-1B B B 2116B
D7971 P X211
/0.0_2.D2 3 768-1C C C 21121 21 K1:21 Analog In 05V
U D7971
SENSOR HYDR. SCALE /0.0_2.C5
HYDRAULIC SCALE LIFT
SENSOR HYDR. SCALE LIFT
B B
C C
B7682 X211
2118C 1 2 2116C 2116A 6 K1:6 0V Ref
P D7971
3 X90064 /0.0_2.D2
U
SENSOR HYDR. SCALE
HYDRAULIC SCALE TILT
X211
21122 22 K1:22 Analog In 05V
D7971
/0.0_2.C5
SENSOR HYDR. SCALE TILT
D D
secuted.
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets överlastsystem DCF300,DCE300 8.2_2
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 Valve blocking tilt removed. 071520 TKB 071030 6
Wiring overloading system A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
C X211 XY6039/6018f XY6039/6018m XB72113f XB72113m C

1.5A K1:36 36 21136 1 1 GY A A
D7971
/0.0_2.D5
MAST POSITION BN
B72113 XB72113m XB72113f XY6040/6019m XY6040/6019f X211
BK C C RD 1 1 21137 37 K1:37 Dig In / 1.5A
D7971
/0.0_2.D5
MAST POSITION OLS
BU MAST POSITION
XY6039/6018m XY6039/6018f
B B BK 2 2 6039 CHASSIS
/ 7.2_2.E5
D D
secuted.
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets givare stativ OLS DCF300,DCE300 8.2_3
CJS 050216 A47137.0100
Name
R
E³ DRAWING
1 Moved from 7.0_6 071520 TKB 071030 6
Wiring sensor mast OLS A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
08712
A 08713 A
D7952
X087f X087f 0876
13 K1:13 CAN 2 K1:6 6
L+ + X90093
12 K1:12 CAN K1:5 5 0875
L
8 K1:8 K1:4 X90094
+ Shield
RS232
K1:11 K1:3 3 30
R+ TX
K1:10 CAN K1:2 2
R RX
K1:7 K1:1 1
+ GND
9 K1:9 0V REF BUZZER K1:14

B B
KID
0878
0879
0871
0872
0592
0591
X088f
25 0872
TX2
26 0873 X059m
RX2 30 1 CAN+
30 08830 X90091 0871 2
C GND CAN C
0878 3
3 0883 +15
+15 0879 5
13 08813 GND
GND X059f
14 0599
Batt+ 9 9 A0599
28 08828
A911 TX1
0895
MIU 29 08829
RX1
D D
secuted.
30
1
2
3
4
5
6
7
8
9
X089m
E E
XF511 F511 XF511 X070m X070f

Batt + GY 1 2 0709 9 9 A0599
/ 11.5_1.D3 1 2
5A
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets RMI DCF300,DCE300 8.2_4
CJS 060529 A47137.0100
Name
R
E³ DRAWING
1 New page 071520 TKB 071030 6
Wiring RMI A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
X211 X213f / 9.6_9.C2 / 9.6_9.C7 X213f

6A K1:42 42 21142 1 24V D7971/1:42 CHASSIS 2 2132 CHASSIS
D7971 / 9.14_1.B2 / 9.14_1.C7 / 7.2_2.E5
/0.0_2.E5
CENTRAL LUB. / WORK LIGHT OPT.
C C
D D
secuted.
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets std. opt. DCF300,DCE300 9.0_1
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring std. opt. A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
(10102)
+CAB
00816E S1992
24V D7901/8:16 X008
/ 7.5_1.D2 1
00814A 14 K8:14 Input
A 0 D7901 A
/ 9.3_3.A2 1 1 /0.0_1.D4
24V D7901/8:16 00816F 5 5
/ 9.10_1.A2 SWITCH S1 OPT.
10 10 9 9 00814B
CHASSIS37D 0923C
/ 7.5_1.D2
/ 9.3_3.A2 0923D
CHASSIS37D
/ 9.10_1.B2
(1019)
B B
+CAB
S1991
1 X080m X080f X006
X005 X081f X081m 0069A 9 9 0069 9 K6:9 Input
24V reference K5:1 1 0051 1 1 0811A 0 D7901
D7901 1 1 /0.0_1.B4
/0.0_1.C1 0811B 5 5
SWITCH S4 OPT.
SWITCHES LEFT PANEL
0812B 10 10 9 9 0069B
OPTION
7901:51/24V 0811
/ 2.0_1.C2
C C
X081m X081f
0812A 2 2 W08 CHASSIS
/ 9.5_1.B8
CHASSIS 0812L
/ 9.1_2.B7
+CAB
S1993
D 1 X080m X080f X006 D
0808A 8 8 0068 8 K6:8 Input
0811B 0 D7901
/0.0_1.B4
secuted.
1 1
0811C 5 5
SWITCH S3 OPT.
0812B 10 10 9 9 0808B
0812C
OPTION
E E
(123)
+CAB
S1994
1 X080m X080f X006
0807A 7 7 0067 7 K6:7 Input
0811C 0 D7901
1 1 /0.0_1.B4
7901:51/24V 0811D 5 5
/ 9.3_1.B2 SWITCH S2 OPT.
0812C 10 10 9 9 0807B
CHASSIS 0812D
/ 9.3_1.B2 OPTION
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets extra utrustning DCF300,DCE300 9.1_1
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring option A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
P708 h
HOUR METER
+
1
2
B B
X010 X039f X039m X081f X081m

0.5A K10:9 9 A0109A 1 1 0391 9 9 0819 0812L CHASSIS
D7901 / 9.1_1.D2
/0.0_1.C6
HOUR MET/RELAY AIR SEAT
7901/10:9 A0109B
/ 9.3_2.B2
C C
D D
secuted.
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets timräknare DCF300,DCE300 9.1_2
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring hour meter A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
When Isringhausen seat:
Switch S143 replaced by
jumper between 1 and 5.
Switch is placed on the seat.
+CAB
S143
1 X080m X080f X006
7901:51/24V 0811E 0806A 6 6 0066 6 K6:6 Input
/ 9.6_4.A2 0 D7901
1 1 /0.0_1.B4
7901:51/24V 0811D 5 5
/ 9.1_1.F2 SWITCH SEAT HEATER
B CHASSIS 0812D 10 10 9 9 0806B B

/ 9.1_1.F2
CHASSIS 0812E SEAT HEATER
/ 9.6_4.B2
C C
K383
X010
0.5A K10:7 7 A0107 86 85 86 85 W05
D7901
/0.0_1.C6
RELAY SEAT HEATER SEAT HEATER
A0634B X37B
584/6:1 30 30 87 87
/ 11.5_2.B6
87A
D D
secuted.
A0634
X063f X063m XE803m XE803f E803 XE803f XE803m X063m X063f

4 4 0634 1 1 YE 1 2 BK 2 2 0633 3 3 W06
SEAT HEATER
X37D
E CHASSIS 0633A E
/ 9.3_2.C7
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets Stolsvärme DCF300,DCE300 9.3_1
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 XE803f and XE803m changed place. 071520 TKB 071030 6
Wiring seat heater A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
K358
7901/10:9 A0109B 86 85 86 85 W07

/ 9.1_2.C2
584/8:1 A0635B 30 30 87 87
/ 11.5_2.B6
B 87A X37B B
COMPRESSOR AIR SEAT
X063m X063f
0635 5 5 A0635
C S268 C
M670
P COMPRESSOR
XM670m XM670f AIRSUSPENDED SEAT XM670f XM670m
1 1 RD 1 + BK 2 2 0633A CHASSIS
M / 9.3_1.E6
COMPRESSOR
AIR CUSHIONED SEAT
D D
secuted.
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets luftfjädrad stol DCF300,DCE300 9.3_2
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring aircushioned seat A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
1 = C.W
0 = 0
+CAB 2 = C.C.W X008
S169 0086 Input
6 K8:6
1 D7901
0 /0.0_1.D4
A 24V D7901/8:16 00816F 2 A
/ 9.1_1.A2 1 1 SWITCH REV. SEAT C.W
24V D7901/8:16 00816G 3 3
/ 7.5_3.B2 7 7 0087
2
4
8
CHASSIS37D 0923D 10 10 9 9 00815B X008
/ 9.1_1.B2
CHASSIS37D 0923E 7 K8:7 Input
/ 7.5_3.B2 REVERSIBLE SEAT D7901
/0.0_1.D4
SWITCH REV. SEAT C.C.W
B B
X008 X092f X092m

1.5A K8:15 15 00815A 2 2 0922A 24V D7901/8:15
D7901 / 7.5_1.B2
/0.0_1.E4
LIGHT SW. S169/S1010
XS720Ff XS720Fm S720F XS720Fm XS720Ff X245f X245m X243m X243f X221
1 1 BU BN 2 2 2453 3 3 2435 5 5 22113 13 K1:13 Analog In 05V
D7972
BK BK/WH /0.0_3.D2
SWITCH SEAT POS. F
C SEAT POS. FRONT C
2451B
X221 X243f X243m X245m X245f XS720Rf XS720Rm S720R XS720Rm XS720Rf X245f X245m X243m X243f X221
1.5A K1:7 7 2217 4 4 2434 1 1 2451A 1 1 BU BN 2 2 2454 4 4 2436 6 6 22120 20 K1:20 Analog In 05V
D7972 D7972
/0.0_3.C2 BK BK/WH /0.0_3.D2
SWITCHES SEAT POS. F/R SWITCH SEAT POS. R
SEAT POS. REAR
D D
secuted.
X6902f X066m
B6902 BK 2 2 0661 1 D7901/6:12
X066m X6902f / 1.0_1.B5
3
5V 2 0662 1 1 RD 1 2 WH 3 3
/ 1.0_1.A4
ACCELERATOR REAR
X066m
0V 3 0663
/ 1.0_1.A6
E E
XS2203m S2203 XS2203m

7901:51/24V 1 BK 1 2 BN 2 7901/6:14
/ 2.0_1.C3 / 2.0_1.C6
BU 3
DECLUTCHING REAR
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets vändbar förarstol DCF300,DCE300 9.3_3
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 Extra declutch added S2203. 071520 TKB 071030 6
Wiring turnable drivers seat A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
H410L
B X221 X247f X247m X270f X270m B
1.5A K1:37 37 22137 1 1 2471 3 3 3 1 1 2 CHASSIS
D7972 / 9.6_7.E8
/0.0_3.D5
LAMP BRAKE LIGHT FORWARD LEFT BRAKE LIGHT FORWARD LEFT
H410R
X221 X247f X247m X271f X271m
1.5A K1:36 36 22136 2 2 2472 3 3 3 1 1 2 CHASSIS
D7972 / 9.6_7.D8
/0.0_3.D5
C C
LAMP BRAKE LIGHT FORWARD RIGHT BRAKE LIGHT FORWARD RIGHT
D D
secuted.
E E
F F

Ruta Sign.
Sq.
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
E401R
X221 X243f X243m X2752f X2752m X2732f X2732m
6A K1:15 15 22115 1 1 2431A 1 1 2431B X90034 2431D 2 2 2A 1 2
D7972
/0.0_3.D2
B B
LAMP DIPPED LIGHT REAR DIPPED LIGHT REAR RIGHT
E401L
X2722f X2722m
2431C 2 2 2A 1 2
DIPPED LIGHT REAR LEFT
E402R2
C X221 X243f X243m X2752f X2752m X2732f X2732m C
6A K1:1 1 2211 2 2 2432A 2 2 2432B X90033 2432D 1 1 1A 1 2 6A CHASSIS
D7972 / 9.6_6.E7
/0.0_3.C2
HEAD LIGHT REAR HEAD LIGHT REAR RIGHT
E402L2
X2722f X2722m
2432C 1 1 1A 1 2 6A CHASSIS
/ 9.6_6.D7
HEAD LIGHT REAR LEFT
D D
secuted.
H413R
X221 X243f X243m X2712f X2712m
1.5A K1:25 25 22125 3 3 2433A X90025 2433B 2 2 2A 1 2 CHASSIS
D7972 / 9.6_7.D8
/0.0_3.C5
LAMP REAR LIGHT FRONT REAR LIGHT FRONT RIGHT
H413L
X2702f X2702m
2433C 2 2 2A 1 2 CHASSIS
/ 9.6_7.E8
REAR LIGHT FRONT LEFT
E E
F F

Ruta Sign.
Sq.
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B Y6361 B
X221 X243f X243m
1.5A K1:9 9 2219 10 10 24310 1 1 2 2 24312B
D7972
/0.0_3.D2
VALVE STEERING FORWARD
STEERING FORWARD
Y6362
X221 X243f X243m X243m X243f
1.5A K1:10 10 22110 11 11 24311 1 1 2 2 24312C X90040 24312A 12 12 W243
D7972
C /0.0_3.D2 C
VALVE STEERING REVERSE
STEERING REVERSE X37216
D D
secuted.
CHASSIS 24312D
/ 9.3_7.C6
E E
F F

Ruta Sign.
Sq.
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
X066f X066m
584/6:2 A0664 4 4 BN
/ 11.5_2.B6
A A
A798
X221 X243f X243m X246f X246m XA7981m
1.5A K1:29 29 22129 8 8 2438 B B RD 5/10
D7972
/0.0_3.D5
VALVE SEAT ROTATION C.W
XA7982m
BN 6/10 1/1 X066m X066f
BU 5 5 A0665
X221 X243f X243m X246f X246m
1.5A K1:39 39 22139 9 9 2439 C C BK 7/10 2/10
D7972
/0.0_3.D5
B B
VALVE SEAT ROTATION C.C.W X37E
BU 8/10 3/10
X221 X243f X243m X246f X246m

1.5A K1:34 34 22134 7 7 2437 A A 9/10 4/10
D7972
/0.0_3.D5
DAMPING TURNABLE SEAT
BU
BN
10/10
WH
C C
A
B
X37798
XM675f
XM675f
Y676
X221 X243Bf X243Bm XY676f XY676m XY676m XY676f
B
1.5A K1:35 35 22135 1 1 243B1 1 1 GY BU 2 2 24312D CHASSIS

D7972 / 9.3_6.D5
XM675m
XM675m
/0.0_3.D5
BRAKE TURNABLE SEAT
BU
BN
TURN SEAT BRAKE M675
31 50
M
TURN SEAT
D D
MOTOR
YE/GN
secuted.
E E
F F

Ruta Sign.
Sq.
CJS 060124 A47137.0100
Name
R
E³ DRAWING
1 Cable BN and BU switched in A798. 071520 TKB 071030 6
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
S246
P
XS2461 XS2462 X211
582/5:1 246-1 1 1 2 1 21140 40 K1:40 Dig In / 1.5A
A / 9.6_5.E2 D7971 A
/0.0_2.E5
REFRIGERANT
PRESSURE SW. REFRIDGE
S118
X005 X033f X033m 1
Analog reference 5V K5:11 11 00511 5 5 0335 0
D7901 2
/0.0_1.D1 1 1 X033m X033f X005
3 3 0331 1 1 0057 7 K5:7 Analog Input
POT. FAN / TEMP / DVALVE 7 7 D7901
/0.0_1.C1
R8206 2
1 2 4 FAN SPEED
8 X033m X033f
8k Ohm 0337 9 9 10 10 0338 8 8 0338 0363 CHASSIS
/ 9.4_2.E7
B X006 X033f X033m FAN SPEED B
PWM K6:1 1 0061 7 7
D7901
/0.0_1.A4
LAMP INST. ILLUMINATION S139 X37D
1
0335A 0
2
1 1 X033m X033f X005
3 3 0333 3 3 0059 9 K5:9 Analog Input
0339A 7 7 D7901
/0.0_1.D1
2
4 DRAUGHT VALVE
8
0337A 9 9 10 10 0338A
DRAUGHT VALVE
C C
S117
X033m 1
9 0339 0
2
0335B 1 1 X033m X033f X005
3 3 0332 2 2 0058 8 K5:8 Analog Input
0339B 7 7 D7901
/0.0_1.D1
2
4 TEMPERATURE
8
0337B 9 9 10 10 0338B
TEMPERATURE
R8207 X005
1 2 4 4 00510 10 K5:10 0V reference
D7901
/0.0_1.D1
D 8k Ohm D
0,5W POT. FAN / TEMP / DEFROST
secuted.
B7751
X035f X035m X7751 X7751 X035m X035f X004
9 9 WH 1 1 T 2 2 YE 7 7 0048 8 K4:8 Reostat in
D7901
WH U /0.0_1.C1
TEMP. INDOOR SENSOR TEMP. INDOOR
10kOhm
B7752
X7752 X7752 X035m X035f X004
00412C
1 1 T 2 2 BU 8 8 00410 10 K4:10 Reostat in
D7901
U /0.0_1.C1
TEMP. FAN AIR SENSOR TEMP. FAN AIR
E 10kOhm at 25°C E
B7753
X036f X036m X7753 X7753 X036m X036f X004
9 9 WH 1 1 T 2 2 YE 8 8 00411 11 K4:11 Reostat in
D7901
U /0.0_1.C1
DEICING SENSOR SENSOR DEICING SENSOR
10kOhm at 25°C
00412B
B774
X004 X039m X039f X065f X065m X774 X774 X065m X065f X039f X039m X004
0V reference K4:12 12 00412A 7 7 A0397 1 1 0651 1 1 T 2 2 0652 2 2 A0399 9 9 0049 9 K4:9 Reostat in
D7901 D7901
/0.0_1.C1 U /0.0_1.C1
F SENSORS AIRCONDITION TEMP. AMBIENT SENSOR TEMP. AMBIENT F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets klimatsystem DCF300,DCE300 9.4_1
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring climate control A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
24V/12V
X004 X035f X035m R6
0.5A K4:4 4 0044 2 2 BK 1 2
A D7901 A
/0.0_1.B1
2 x 47 Ohm
MOTOR DRAUGHT VALVE
X004 X035f X035m R5 Y672 DRAUGHT VALVE
0.5A K4:3 3 0043 1 1 RD 1 2
D7901 5 M 6
/0.0_1.B1
MOTOR DRAUGHT VALVE
X004 X035f X035m X035m X035f X004
Analog reference 5V K4:5 5 0045A 4 4 GN BN 6 6 0046A 6 K4:6 0V reference
D7901 10 8 D7901
/0.0_1.B1 /0.0_1.B1
9
POT. DRAUGHT/WAT. VALVE POT. DRAUGHT/ WAT VALVE
X035m X035f X004
OG 5 5 0047 7 K4:7 Analog Input
D7901
/0.0_1.B1
0045B
24V / 12V
POT. DRAUGHT VALVE
X004 X034f X034m R4
0.5A K4:2 2 0042 5 5 BK 1 2
B D7901 B
/0.0_1.B1
2 x 220 Ohm
MOTOR WATER VALVE WATER VALVE
0046B
X004 X034f X034m R3 Y673
0.5A K4:1 1 0041 4 4 RD 1 2 5 6
D7901 M
/0.0_1.B1
MOTOR WATER VALVE
X034f X034m X034m X034f
7 7 GN 10 8 BN 9 9
9 X034m X034f X039m X039f X010

OG 8 8 0398 8 8 A0104 4 K10:4 Analog Input
D7901
/0.0_1.B6
POT. WATER VALVE
M657
C X039f X039m X034f X034m X657f X657m C
585/3:1 A0396 6 6 0396 1 1 OG 1 1 OG
/ 11.5_2.D6 1
X002 X062f X062m X034f X034m X657f X657m
PWM K2:2 2 A0022 8 8 0628 2 2 BK 2 2 BK
D7901 31
/0.0_1.B1
MOTOR HEATING FAN HEATING FAN
X002
585/3:2 A0028 A0028 8 K2:8
/ 11.5_2.D6 D7901
/0.0_1.B1
24/12v LOGIC SUPPLY HEAT FAN
D D
X039f X039m X036f X036m R1
secuted.
585/4:1 A0395 5 5 0395 1 1 RD 1 2 X612f X612m M612
/ 11.5_2.D6
82 Ohm RD 1 1 RD
+12V
BK 2 2 GY
GND M
BU BU 3 3 BU
Signal
X002 X062f X062m X036f X036m
1.5 A0023 0629 MOTOR, RECIRCULATION
K2:3 3 9 9 2 2
D7901
/0.0_1.B1
MOTOR RECIRCULATION
E E
X036m X036f
M645 BK 3 3 0363 CHASSIS
/ 9.4_1.B7
X211 X278f X278m X645
1.5A K1:25 25 21125A X90013 21125B 1 1 2781 1 2
D7971
/0.0_2.D5 1
COMPRESSOR AIRCONDITION
COMPRESSOR
X211
1.5A K1:29 29 21129
D7971
/0.0_2.D5
F COMPRESSOR AIRCONDITION F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets klimatsystem DCF300,DCE300 9.4_2
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring climate control A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
S162 MULTISWITCH
X017 X017
24V reference K3:5 5 RD 15 53C GY 4 K3:4 Input
A D7902 D7902 A
/11.5_4.F4 /11.5_4.F4
SWITCH MULTIFUNCTION SWITCH FLUSHING
X017
J1 GN 6 K3:6 Input
D7902
/11.5_4.F4
SWITCH WIPER FRONT
X017
J2 BK 7 K3:7 Input
D7902
/11.5_4.F4
SWITCH WIPER FRONT
X017
53 BU 8 K3:8 Input
D7902
/9.7_1.B1 /11.5_4.F4
SWITCH WIPER FRONT
WIPER /9.6_4.E5
B /2.0_1.B5 B
31
XM6501m XM6501f
BK 4 4 W01 W08 CHASSIS
/ 9.1_1.D7
M6501 M
X002 X062f X062m XM6501f XM6501m FRONT WIPER
5A K2:1 1 A0021 7 7 0627 2 2 RD
D7901

/0.0_1.B1
53
X37D
53a
53b
31b
MOTOR FRONT WIPER
X004 XM6501f XM6501m
24V reference K4:14 14 00414 1 1 YE
D7901
/0.0_1.C1
XM6501m XM6501f X004
C MOTOR FRONT WIPER GN 3 3 00413 13 K4:13 Input C
D7901
/0.0_1.C1
MOTOR FRONT WIPER
M6502
X002 X057f X057m XM6502f XM6502m XM6502m XM6502f X057m X057f
5A K2:4 4 A0024 1 1 0571 1 1 YE 53 31 BN 2 2 0574 4 4
D7901 M
/0.0_1.B1
MOTOR REAR WIPER
X012 X057f X057m XM6502f XM6502m 31b XM6502m XM6502f X057m X057f X012
24V reference K12:1 1 A0121 3 3 0573 4 4 BK/GN 53a BK 3 3 0572 2 2 A0122 2 K12:2 Input
D7901 D7901
/0.0_1.D6 REAR WIPER /0.0_1.D6
D MOTOR REAR WIPER MOTOR REAR WIPER D
A0574
secuted.
M6503
X010 X055f X055m XM6503f XM6503m XM6503m XM6503f X055m X055f
1.5A K10:14 14 A01014 1 1 0551 1 1 YE 53 31 BN 2 2 0554 4 4 A0554 X37B
D7901 M
/0.0_1.C6
MOTOR ROOF WIPER
X012 X055f X055m XM6503f XM6503m 31b XM6503m XM6503f X055m X055f X012
24V reference K12:3 3 A0123 3 3 0553 4 4 BK/GN 53a BK 3 3 0552 2 2 A0124 4 K12:4 Input
D7901 D7901
/0.0_1.D6 ROOF WIPER /0.0_1.E6
MOTOR ROOF WIPER MOTOR ROOF WIPER
E M6511 E
WASHER FRONT
X010 X058f X058m XM6511 XM6511 X058m X058f
3A K10:13 13 A01013 1 1 0581 1 + 2 0582 2 2 A0582
D7901 M
/0.0_1.C6
MOTOR WASHER
X37B
M6512
WASHER REAR & ROOF
X058f X058m XM6512 XM6512 X058m X058f X040f X040m X005
F A01013A 3 3 0583 1 + 2 0584 4 4 A0402 2 2 0054 4 K5:4 PWM (NPN) F
M D7901
/0.0_1.C1
MOTOR WASH REAR/ROOF

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets torkare DCF300,DCE300 9.5_1
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring wiper function A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
S1051
1 X080m X080f X006
00610A 1 1 00610 10 K6:10 Input
0 D7901
1 1 /0.0_1.B4
7901:51/24V 0811I 5 5
/ 9.6_2.B2 SW WORK LIGHTS MAST
A A
CHASSIS 0812J 10 10 9 9 00610B
/ 9.6_2.B2
WORK LIGHTS 2040
K30171
X010
0.5A K10:8 8 A0108 86 86 85 85 W02
D7901
/0.0_1.C6
CONTAINER LIGHT 40
584/7:2 A0545B 30 30 87 87
/ 11.5_2.B6
87A
B CONTAINER LIGHT 40 B
A0565
X37A
A0563
E406L1
X056f X056m XE406L1f XE406L1m XE406L1m XE406L1f
3 3 0563 1 1 GY 1 1 2 2 BK 2 2 0567A
CONTAINER LIGHT 40
C C
E406R1
X056f X056m XE406R1f XE406R1m XE406R1m XE406R1f X056m X056f
5 5 0565 1 1 GY 1 1 2 2 BK 2 2 0567B 7 7 A0567
CONTAINER LIGHT 40 X37E
K30172
X007 X069m X069f
0.5A K7:8 8 0078 1 1 A0691 86 86 85 85 W02A
D7901
D /0.0_1.C4 D
CONTAINER LIGHT 20
secuted.
584/7:2 A0545C 30 30 87 87
/ 11.5_2.B6
87A
CONTAINER LIGHT 20
A0564
A0562 X37C
E406L2
X056f X056m XE406L2f XE406L2m XE406L2m XE406L2f
2 2 0562 1 1 GY 1 1 2 2 BK 2 2 0566A
E E
CONTAINER LIGHT 20
E406R2
X056f X056m XE406R2f XE406R2m XE406R2m XE406R2f X056m X056f
4 4 0564 1 1 GY 1 1 2 2 BK 2 2 0566B 6 6 A0566
F F
CONTAINER LIGHT 20 X37E

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets arbetsljus 2040 DCF300,DCE300 9.6_1
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring work lights 2040 A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
S1052
1 X080m X080f X006
7901:51/24V 0811H 0062A 2 2 0062 2 K6:2 Input
/ 9.6_3.B2 0 D7901
1 1 /0.0_1.A4
7901:51/24V 0811I 5 5
/ 9.6_1.A2 SW WLIGHTS CARRIAGE
B B
CHASSIS 0812J 10 10 9 9 0062B
/ 9.6_1.A2
CHASSIS 0812I WORK LIGHTS CARRIAGE
/ 9.6_3.B2
24V D7911/1:1 CHASSIS
/ 9.6_14.B2 / 9.6_14.B7
C C
E404L3
X421 XE404L3f XE404L3f
6A K1:1 1 4211 1 1 2 2 W4211 4054 CHASSIS
D791 / 7.9_1.E7
/0.0_4.C2
WORK LIGHT LEFT WORK LIGHT CARRIAGE LEFT
24V D7911/1:15 CHASSIS
/ 9.6_14.E2 / 9.6_14.E7
E404R3
X421 XE404R3f XE404R3f
6A K1:15 15 42115 1 1 2 2 W42115 W400 CHASSIS
D D791 / 11.5_5.B7 D
/0.0_4.D2 X90061
WORK LIGHT RIGHT
secuted.
WORK LIGHT CARRIAGE RIGHT
W42114 CHASSIS
/ 9.14_1.E7
E E
W9003 CHASSIS
/ 7.5_3.E7
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets arbetsljus vagn DCF300,DCE300 9.6_2
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 Extra worklight added. 071520 TKB 071030 6
Wiring work lights carriage A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B S1053 B
1 X080m X080f X006
7901:51/24V 0811G 0063A 3 3 0063 3 K6:3 Input
/ 9.6_4.C2 0 D7901
1 1 /0.0_1.B4
7901:51/24V 0811H 5 5
/ 9.6_2.B2 SW WORK LIGHTS MAST
CHASSIS 0812I 10 10 9 9 0063B
/ 9.6_2.B2
CHASSIS 0812H WORK LIGHTS MAST
/ 9.6_4.C2
C C
D D
E404L1
X211 X204m X204f X2041f X2041f X204f X204m
6A X90019
secuted.
K1:1 1 2111A 2111B 1 1 2041 1 1 2 2 2043 3 3 W2043
D7971
/0.0_2.C2
LAMPS WORK LIGHT MAST WORK LIGHT MAST
E404R1
X204m X204f X2042f X2042f X204f X204m
2111C 2 2 2042 1 1 2 2 2044 4 4 W2044 W204
X90078
WORK LIGHT MAST X37201A
E X37201 E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets arbetsljus stativ DCF300,DCE300 9.6_3
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 Kablage till 5298 utgår 071520 TKB 071030 6
Wiring work lights mast A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
S100
1 X080m X080f X006
0065A 5 5 0065 5 K6:5 Input
7901:51/24V 0811E 0 D7901
/ 9.3_1.B2 1 1 /0.0_1.B4
5 5
SWITCH MAIN LIGHT
CHASSIS 0812E 10 10 9 9 0065B
/ 9.3_1.B2
CHASSIS 0812F
/ 9.6_7.A2 MAIN LIGHT
B B
0811F
S110
1 X080m X080f X006
0064A 4 4 0064 4 K6:4 Input
0 D7901
1 1 /0.0_1.B4
7901:51/24V 0811G 5 5
/ 9.6_3.B2 SWITCH ROT. BEACON
CHASSIS 0812G 10 10 9 9 0064B
/ 9.6_7.B2
CHASSIS 0812H
/ 9.6_3.C2 ROT. BEACON
C C
S162 MULTISWITCH
D D
56 56b
secuted.
X017
56a WH 9 K3:9 Input
D7902
/11.5_4.F4
SWITCH MAIN / DIPPED BEAM
/2.0_1.A4
MAIN / DIPPED BEAM /9.5_1.B4
E X002 X056f E
5A K2:5 5 A0025 1
D7901
/0.0_1.B1
MOTOR ROT. BEACON
H428
ROT. BEACON
X054f X054m X4281 X4282 X054m X054f
A0547 7 7 0547 1 + 1 0548 8 8 A0548
M
F X37B F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets belysning DCF300,DCE300 9.6_4
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring lights A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
270:2 270:2 E400L

A X270f / 9.6_13.A1 / 9.6_13.A8 X270m A
21128C 2 2 2 1 1 2
DIPPED LIGHT FRONT LEFT
271:2 271:2 E400R

X211 X271f / 9.6_13.C1 / 9.6_13.C8 X271m
6A K1:28 28 21128A X90028 21128B 2 2 2 1 1 2
D7971
/0.0_2.D5
LAMP DIPPED LIGHT DIPPED LIGHT FRONT RIGHT
B B
X270/271f X211:1 X270/271m 270:1 E402L1

/ 9.6_13.E2 X270f / 9.6_13.A1 X270m
21115C 1 1 21115D 1 1 1 1 1 2 1 6A
24VK304287
/ 9.6_13.F5
HEAD LIGHT FRONT LEFT
6B CHASSIS
/ 9.6_7.E8
X270/271f X270/271m 271:1 E402R1
X211 X271f / 9.6_13.C1 X271m
6A K1:15 15 21115A X90027 21115B 2 2 21115E 1 1 1 1 1 2 1 6A
D7971
/0.0_2.D2 24VK304287
/ 9.6_13.F5
HEAD LIGHT HEAD LIGHT FRONT RIGHT
C C
270:5 270:5 H4161 X270m 270:6 270:6 X270f

X211 X270f / 9.6_13.A1 / 9.6_13.A8 X270m / 9.6_13.A8 / 9.6_13.A1
1.5A K1:2 2 2112A X90006 2112B 5 5 5 1 1 2 1 6C 6 6 6 2706
D7971
/0.0_2.C2 X90047
SIDE POSITION LIGHT SIDE POSITION FRONT LEFT
6B CHASSIS
/ 9.6_7.D8
271:5 271:5 H4171 X271m 271:6 271:6 X271f

X271f / 9.6_13.D1 / 9.6_13.D8 X271m / 9.6_13.D8 / 9.6_13.D1
D 2112C 5 5 5 1 1 2 1 6C 6 6 6 2716 D
X90046
X37207A
secuted.
SIDE POSITION FRONT RIGHT
X37207
2112D 2112
/ 9.6_6.D2
582/5:1 771A S216

/ 7.7_2.C2
582/5:1 2481
/ 7.2_6.E1 P
582/5:1 246-1 X211
/ 9.4_1.A2
582/5:1 216-246 X90043 216-1A 1 2 21120 20 K1:20 Analog In 05V
/ 11.5_1.B8 D7971
582/5:1 216-1B /0.0_2.E2
E / 2.0_1.C2 BRAKE LIGHTS E
PRESSURE SWITCH BRAKE LIGHT
F F

Ruta Sign.
Sq.
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 X270/271 and ref to 9.6_13 added. 071520 TKB 071030 6
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
E405L
X056f X056m
A0543 9 9 0569A 1 1 2 1 0569B
REVERSING LIGHT REAR LEFT
A A
E405L
X002 X054f X054m X054m X054f
5A K2:6 6 A0026 3 3 0543 1 1 2 2 0544 4 4 A0544
D7901
/0.0_1.B1
REVERSING LIGHT LEFT REVERSING LIGHT REAR LEFT
E405R
X056f X056m
A0545 8 8 0568A 1 1 2 1 0568B
REVERSING LIGHT REAR RIGHT
E405R X37C
X002 X054f X054m X054m X054f
5A K2:7 7 A0027 5 5 0545 1 1 2 2 0546 6 6 A0546
B D7901 B
/0.0_1.B1
REVERSING LIGHT RIGHT REVERSING LIGHT REAR RIGHT
X37A
H411L
X211 X275f X275m X272f X272m
1.5A K1:7 7 2117 3 3 2753 3 3 3 1 2
D7971
/0.0_2.D2
BRAKE LIGHT LEFT BRAKE LIGHT REAR LEFT
C H411R C
X211 X275f X275m X273f X273m
1.5A K1:9 9 2119 4 4 2754 3 3 3 1 2
D7971
/0.0_2.D2
BRAKE LIGHT RIGHT BRAKE LIGHT REAR RIGHT
CHASSIS
H412L / 9.6_7.E8
X211 X275f X275m X272f X272m
1.5A K1:33 33 21133 5 5 2755A X90007 2755B 2 2 2 1 2 6B
D7971
/0.0_2.D5
6A CHASSIS
REAR LIGHTS REAR LIGHT LEFT / 9.3_5.D7
D D
secuted.
H4162
X275f X275m X272f X272m X272m X272f X275m X275f
2112 2112D 6 6 2756A X90024 2756B 5 5 5 1 2 6C 6 6 6 2726 8 8 2758
/ 9.6_5.D6
X90049
SIDE POSITION REAR LEFT
CHASSIS
H412R / 9.6_7.D8
X273f X273m
2755C 2 2 2 1 2 6B
E 6A CHASSIS E
REAR LIGHT RIGHT / 9.3_5.C7
H4172
X273f X273m X273m X273f X275m X275f
2756C 5 5 5 1 2 6C 6 6 6 2736 7 7 2757
X90048
SIDE POSITION REAR RIGHT
X37204
F F

Ruta Sign.
Sq.
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 Jordning lampor ändrad. 071520 TKB 071030 6
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A S109 A
1
0 X081m X081f X005
X039f X039m X081f X081m 1 1 0816 6 6 0056 6 K5:6 Input
584/2:2 A0392 2 2 0392 7 7 0817 5 5 D7901
/ 11.5_2.A6 /0.0_1.C1
CHASSIS 0812F 10 10 9 9 0815 5 5 SWITCH HAZARD
/ 9.6_4.B2
CHASSIS 0812G Hazard
/ 9.6_4.C2 X005
0055 5 K5:5 PWM (PNP)
D7901
/0.0_1.C1
SWITCH LAMP HAZARD
B B
S161
R
0
L X018
1 1 0189 9 K8:9 Input
D7902
0187B 2 2 3 /11.5_4.F4
SWITCH DIRECTION LIGHT RIGHT
X018
1.5A K8:7 7 0187A 5 5 4
D7902 X018
/11.5_4.F4 6 6 0188 8 K8:8 Input
C D7902 C
SWITCH DIRECTION LIGHT /11.5_4.F4
DIRECTION LIGHT SWITCH DIRECTION LIGHT LEFT
271:4 271:4 H423 CHASSIS

X211 X271f / 9.6_13.C1 / 9.6_13.C8 X271m / 9.3_5.D7
2.5A K1:31 31 21131A X90065 21131B 4 4 4 1 1 2 1 6B CHASSIS
D7971 / 9.6_5.D7
/0.0_2.D5 CHASSIS
D / 9.3_4.C7 D
LAMP DIRECTION RIGHT Direction Right Front
secuted.
H427
X275f X275m X273f X273m
21131C 2 2 2752 4 4 4 1 1 2 CHASSIS
/ 9.6_6.E7
Direction Right Rear
270:4 270:4 H422 CHASSIS

X211 X270f / 9.6_13.A1 / 9.6_13.A8 X270m / 9.3_4.B7
2.5A K1:30 30 21130A X90003 21130B 4 4 4 1 1 2 1 6B CHASSIS
D7971 / 9.6_5.C7
/0.0_2.D5 CHASSIS
E / 9.3_5.E7 E
LAMP DIRECTION LEFT Direction Left Front
H426
X275f X275m X272f X272m
21130C 1 1 2751 4 4 4 1 1 2 CHASSIS
/ 9.6_6.D7
Direction Left Rear
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets blinkers & hazard DCF300,DCE300 9.6_7
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 Ref to 9.6_13 added. 071520 TKB 071030 6
Wiring light director & hazard A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A0668 584/2:1
/ 9.6_11.B1
A A
X060f X060m X060Af X060Am X018 X018 X060Am X060Af X060m X060f X011
584/2:1 A0607 7 7 0607 7 7 0607B 10 K8:10 K8:11 11 0609 9 9 0609 9 9 A0112 2 K11:2 Input
/ 11.5_2.A6 D7902 D7902 D7901
/0.0_1.C6
SWITCH INTERIOR LIGHT SWITCH INTERIOR LIGHT INTERIOR LIGHT
584/2:1 0607A
/ 11.5_3.C2
INTERIOR LIGHT SWITCH DISPLAY
B B
X039f X039m X082f X082m S266LE X082m X082f X039m X039f X011
584/2:1 A0393 3 3 0393A 1 1 0393C 1 1 2 1 0394C 2 2 0394A 4 4 A0113 3 K11:3 Input
/ 11.5_2.A6 D7901
/0.0_1.C6
BRAKING CAB DOOR
SWITCH BREAK CAB DOOR
S266RI
C 0393B 1 1 2 1 0394B C
BRAKING CAB DOOR
E4341
X011 X054f X054m X054m X054f
1.5A K11:6 6 A0116 1 1 0541 1 1 2 1 0542 2 2 A0542A
D7901
/0.0_1.D6
LAMP INTERIOR LIGHT INTERIOR LIGHT
D D
secuted.
X066f X066f
A0541 6 24V D7901/11:6 CHASSIS 7 A0542B
/ 9.6_11.C1 / 9.6_11.C7
E E
E4342
X062f X062m XE4342f XE4342m XE4342m XE4342f X062m X062f
585/6:1 A0624 4 4 0624 1 1 BK 1 2 1 2 BK 2 2 0625 5 5 A0625
/ 11.5_2.E6
MAP LIGHT
X37A
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets innerbelysning DCF300,DCE300 9.6_8
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring interior lights A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
E404R4
X213m XE404R4f XE404R4f X213m
24V D7971/1:42 1 2131A X90062 2131B 1 1 2 2 2132B 2132A 2 CHASSIS
/ 9.0_1.C4 / 9.0_1.C6
X90063
WORK LIGHT OPT
C C
E404L4
XE404L4f XE404L4f
2131C 1 1 2 2 2132C
WORK LIGHT OPT
D D
secuted.
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets arbetsljus option DCF300,DCE300 9.6_9
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 Kablage till 5298 utgår 071520 TKB 071030 6
Wiring work lights option A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
E404R2
XE404R2f XE404R2f
2491C 1 1 2 2 2492C
C C
WORK LIGHT OPT
E404L2
X249m XE404L2f XE404L2f X249m
D7972/1:42 1 2491A X90042 2491B 1 1 2 2 2492B 2492A 2 CHASSIS
/ 11.5_9.D3 / 11.5_9.D6
X90041
WORK LIGHT OPT
D D
secuted.
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets arbetsljus option DCF300,DCE300 9.6_10
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 Kablage till 5298 U. X249 v X240. 071520 TKB 071030 6
Wiring work lights option A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
X066f X066m X276f X276m XS141f XS141m S141 XS141m XS141f X276m X276f X066m X066f X011
584/2:1 A0668 8 8 GY 1 1 GY 1 1 BN 1 2 BK 2 2 BK 2 2 BK 9 9 A0114 4 K11:4 Input
/ 9.6_8.A2 D7901
/0.0_1.D6
STEP LIGHT
SWITCH STEP IN LIGHT
B B
C C
E433
X066m X276f X276m X276m X276f X066m
24V D7901/11:6 6 RD 3 3 GY 1 1 2 1 BK 4 4 BU 7 CHASSIS
/ 9.6_8.D3 / 9.6_8.D6
STEP LIGHT
D D
secuted.
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets instegsbelysning DCF300,DCE300 9.6_11
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring step in light A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
E404L5
XE404L3m XE404L5f XE404L5f XE404L3m
Kopplas till kontakt för std belyning. 1 4211A X90085 4211B 1 1 2 2 W4211B X90087 W4211A 2
Kopplas till kontakt för std belyning.
B B
Connected to connector std work light. Connected to connector std work light.
WORK LIGHT CARRIAGE LEFT OPT
XE404L3f XE404L3f
4211C 1
Std belysning 2 W4211C
Std work light
C C
E404R5
XE404R3m XE404R5f XE404R5f XE404R3m
Kopplas till kontakt för std belyning. 1 42115A X90086 42115B 1 1 2 2 W42115B X90088 W42115A 2
Kopplas till kontakt för std belyning.
Connected to connector std work light. Connected to connector std work light.
WORK LIGHT CARRIAGE RIGHT OPT
D XE404R3f XE404R3f D
42115C 1
Std belysning 2 W42115C
secuted.
Std work light
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets extra bel. aggr DCF300,DCE300 9.6_12
CJS 050405 A47137.0100
Name
R
E³ DRAWING
Wiring work lights carriage opt A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
X270Am
270:1 1 1 X270Af
/ 9.6_5.B4
A 270:2 2 2 2 2 270:2 A
/ 9.6_5.A3 / 9.6_5.A5
3 3 3 3
270:4 4 4 4 4 270:4
/ 9.6_7.E4 / 9.6_7.E5
270:5 5 5 5 5 270:5
/ 9.6_5.C3 / 9.6_5.C5
270:6 6 6 6A 6 270:6
/ 9.6_5.C8 / 9.6_5.C7
E4047L
1A 1 2 6B
B B
OPT. WORKING LIGHT FRONT LEFT
E4048L
1B 1 2 6C
OPT. WORKING LIGHT FRONT LEFT
C C
X271Am
271:1 1 1 X271Af
/ 9.6_5.C4
271:2 2 2 2 2 271:2
/ 9.6_5.B3 / 9.6_5.B5
3 3 3 3
271:4 4 4 4 4 271:4
/ 9.6_7.D4 / 9.6_7.D5
271:5 5 5 5 5 271:5
/ 9.6_5.D3 / 9.6_5.D5
271:6 6 6 6A 6 271:6
/ 9.6_5.D8 / 9.6_5.D7
D D
E4047R
secuted.
1A 1 2 6B
OPT. WORKING LIGHT FRONT RIGHT
E4048R
1B 1 2 6C
OPT. WORKING LIGHT FRONT RIGHT
E E
K3042
X270/271m
X211:1 1 GY 86 86 85 85 W304-2-85
/ 9.6_5.B3
X270/271f X37200R
581/8:1 W304-2-30A 30 30 87 87 BK 1 24VK304287
/ 11.5_1.C5 / 9.6_5.B3
87A RD 2 24VK304287
/ 9.6_5.C3
WORK LIGHTS
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets arbetsljus option lamphuv DCF300, DCE300 9.6_13
CJS 060823 A47137.0100
Name
R
E³ DRAWING
1 New page 071520 TKB 071030 6
Wiring work lights option fenders A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
E404L1
XE404m XE404m
24V D7911/1:1 1 4041A XSP4041 4041B 1 1 2 2 4042B XSP4042 4042A 2 CHASSIS
/ 9.6_2.C4 / 9.6_2.C5
WORK LIGHT CARRIAGE LEFT
E404L2
4041C 1 1 2 2 4042C
WORK LIGHT CARRIAGE EXTRA LEFT
C C
D D
secuted.
E404R1
XE404Rm XE404Rm
24V D7911/1:15 1 4041A XSP4041 4041B 1 1 2 2 4042B XSP4042 4042A 2 CHASSIS
/ 9.6_2.D4 / 9.6_2.D5
WORK LIGHT CARRIAGE RIGHT
E404R2
E 4041C 1 1 2 2 4042C E
WORK LIGHT CARRIAGE EXTRA RIGHT
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets arbetsljus option vagn DCF300, DCE300 9.6_14
CJS 070921 A47137.0100
Name
R
E³ DRAWING
New drawing 071520 TKB 071030 6
Wiring work lights option carriage A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
S162 MULTISWITCH
/9.5_1.B4
X017
H BN 2 K3:2 Input
D7902
/11.5_4.F4
SWITCH HORN
HORN
B B
X011 X062f X062m H850

3A K11:11 11 A01111A 1 1 0621 +
D7901
/0.0_1.D6 0622
HORN
Horn
0621 A01111B
/ 9.7_3.B2
0622A CHASSIS
/ 9.7_3.C7
X062f X062m
C 2 2 C
A0622
X37B
X011 X063f X063m X230f X230m S230 X230m X230f X063m X063f X011
24V reference K11:12 12 A01112 1 1 0631 2 2 BU 2 1 RD 1 1 0632 2 2 A01114 14 K11:14 Input
D D7901 D7901 D
/0.0_1.D6 3 GY 3 /0.0_1.D6
SWITCH SEAT SWITCH SEAT
secuted.
SEAT SWITCH
H853
X018 XH853f XH853m XH853m XH853f

1.5A K8:4 4 0184 1 1 RD 1 2 BK 2 2 02014 7902/1:14
D7902 / 11.6_1.B2
/11.5_4.F4
BUZZER
BUZZER
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets larm, ljudsignaler DCF300,DCE300 9.7_1
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring alarm, buzzer and horn A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
X211 X275f X275m XH965f XH965m H965

1.5A K1:10 10 21110 9 9 2759 1 1 RD +
D7971
/0.0_2.D2 10 10 27510 2 2 BK
REVERSING ALARM
REVERSING ALARM
C C
37210 2023 CHASSIS

/ 7.0_5.D2
X37210
D D
secuted.
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets backalarm DCF300,DCE300 9.7_2
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring reversing alarm A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
K3016
0621 A01111B 86 85 86 85 W04

/ 9.7_1.C2
/9.7_3.C4
COMPRESSOR HORN
B X37B B
H8501
COMPRESSOR HORN
K3016 X062f X062m
585/8:1 A0623A 30 30 87 87 A0623B 3 3 0623 1 + 1 0622A CHASSIS
/ 11.5_2.E6 M / 9.7_1.C7
87A
/9.7_3.B4
COMPRESSOR HORN
C C
D D
secuted.
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets kompressor horn DCF300,DCE300 9.7_3
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring compressor horn A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
S1493
1
24V D7901/8:16 0921B 0 X091m X091f X009
/ 7.9_1.B2 1 0911 1 1 00910 10 K9:10 Input
24V D7901/8:16 0921C 2 D7901
B / 7.5_1.B2 B
HORN SERVO PANEL OPT. HORN SERVO PANEL OPT.
C C
D D
secuted.
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets tuta servopanel DCF300,DCE300 9.7_4
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 Connection S1493 v 51, now 21 071520 TKB 071030 6
Wiring horn servo panel A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
X900Af X900Bf
1/8 1/8
2/8 2/8 H902R
X900Bm
3/8 3/8 3 BK/WH +
X055f X055m X900Am
584/5:1 A0555 5 5 0555 4 4/8 4/8 4 BK
/ 11.5_2.B6
5/8 5/8 5 BK/WH
SPEAKER RIGHT
6/8 6/8 6 BK
X055f X055m X900Am
584/3:2 A0559 9 9 0559 7 7/8 7/8
/ 11.5_2.B6
A0557 7 7 0557 8 8/8 8/8
B H902L B
+

SPEAKER LEFT
A900
C C
A0557
D D
secuted.
X37C
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets radio DCF300,DCE300 9.8_1
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring radio A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
+12V RD 12V
/ 11.5_7.D6
CHASSIS BK
/ 11.5_7.D6
5V
XA9092f
X182m X182f XA9092m
KID_RX 1822 2 2 90922 TX
/ 11.6_1.A2
KID_TX 1823 3 3 90923 RX
/ 11.6_1.A2
KID_GND 1825 5 5 90925 GND

/ 11.6_1.A2
B A909 B
Printer
C C
D D
secuted.
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets skrivare DCF300,DCE300 9.8_2
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring printer A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
Strömbrytare 123, se sida 9.1_1
B B
/Switch 123, see page 9.1_1
X241m XE802Rf XE802Rm E802R1 XE802Rm XE802Rf X241m
24V D7972/1:11 2 GY 1 1 BN 1 2 BU 2 2 BK 1 CHASSIS
/ 11.5_11.B3 / 11.5_11.B6
E802R2
BN 1 2 BU
C C
X241m XE802Lf XE802Lm E802L1 XE802Lm XE802Lf X241m

24V D7972/1:12 3 GY 1 1 BN 1 2 BU 2 2 BK 4 CHASSIS
/ 11.5_11.C3 / 11.5_11.D6
E802L2
BN 1 2 BU
D D
secuted.
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets värme backspeglar DCF300,DCE300 9.9_1
CJS 050223 A47137.0100
Name
R
E³ DRAWING
Wiring heating mirrors A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
WHEN BOTH CAMERAS ARE USED CONNECT CORE GN TO X056:8 OR X054:5
B B
1
A907
X057f X057m X265f X265m XA907f

A0577 RD RD XA907m
585/4:2 7 7 1 1 1
/ 11.5_2.D6
X265f X265m A9081
GN 2 2 GN 3 XCA2f XCA2m XA9081f XA9081m
+24V on CORE GN WILL ALWAYS DISPLAY THE REAR CAMERA BK BK
3 3 4
C C
Front Camera
A9082
XCA1f XCA1m XA9082f XA9082m
D Rear Camera D
secuted.
Monitor
E E
X057m X057f
BK 9 9 A0579
X37E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets kamera DCF300,DCE300 9.9_2
CJS 050223 A47137.0100
Name
R
E³ DRAWING
1 Added connection for automatic display change. 071520 TKB 071030 6
Wiring camera A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
Strömställare val manuell/automatisk hyttippning se S1992.
Switch choice manual/automatic cab tilt see S1992. 1 = UP/RIGHT
0 = 0
A 2 = DOWN/LEFT X008 A
S1010 0086 Input
6 K8:6
24V D7901/8:16 00816F 1 D7901
/ 9.1_1.A2 0
2
1 1 SWITCH CAB TILT UP/RIGHT
24V D7901/8:16 00816G 3 3
/ 7.5_3.B2 7 7
2
4
8 X008
CHASSIS37D 0923D 10 10 9 9 00815B 0087 7 K8:7 Input
/ 9.1_1.B2 D7901
CHASSIS37D 0923E
/ 7.5_3.B2 CAB TILT/SLIDING CAB
SWITCH CAB TILT DOWN/LEFT
X008 X092f X092m

B 1.5A K8:15 15 00815A 2 2 0922A 24V D7901/8:15 B
D7901 / 7.5_1.B2
LIGHT SW. S169/S1010
Y6080
X221 X243f X243m X243m
1.5A K1:25 25 22125 3 3 GY 1 1 2 2 BK 12
D7972
Endast vid hyttkörning, ej hyttilt. ACT. SLIDING CAB
Only for sliding cab, not cab tilt.
C C
Y6047
X221 X243f X243m
1.5A K1:29 29 22129 8 8 2438 1 1 2 2 24312B
D7972
CAB TILT UP/RIGHT
Y6048
X221 X243f X243m X243m X243f
1.5A K1:39 39 22139 9 9 2439 1 1 2 2 24312C 24312A 12 12 W243
D7972
X90067
D CAB TILT DOWN/LEFT X37216 D
secuted.
X221 X243f X243m XB7691f XB7691m
1.5A K1:7 7 2217 4 4 2434A X90066 2434B A A
D7972
BN
B7691 XB7691m XB7691f X243m X243f X221
BK C C 2435 5 5 22113 13 K1:13 Input
D7972
CAB TILT UP
BU
B B 24312D
E E
XB7692f XB7692m
2434C A A
BN
B7692 XB7692m XB7692f X243m X243f X221
BK C C 2436 6 6 22120 20 K1:20 Input
D7972
CAB TILT DOWN
Endast vid hyttilt, ej hyttkörning. BU
B B 24312E
Only for cab tilt, not sliding cab.
F F
Givare stativ för automatisk hyttilt se B72111.
Sensor mast when automatic cab tilt see B72111.
Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets hyttilt/hyttkörning DCF300,DCE300 9.10_1
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 Cable 00815C U 071520 TKB 071030 6
Wiring cab tilt/sliding cab A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
M6931
1
GREY
2
B X213m XM6931 B
24V D7971/1:42 1 1 15
/ 9.0_1.C4 M
31 BLACK
2
CENTRAL LUBRICATION
X213m
2 CHASSIS
/ 9.0_1.C6
C C
M6932
1
D GREY D
2
secuted.
X421 XM6932
10A K1:14 14 42114 1 15
D791 M
/0.0_4.D2 BLACK
2 31
PUMP CENTRAL LUBRICATION
CENTRAL LUBRICATION
E W42114 CHASSIS E
/ 9.6_2.E8
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets centralsmörjning DCF300,DCE300 9.14_1
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring central lubrication A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
Y6062
X211
1.5A K1:39 39 21139 1 1 2 2 6062 CHASSIS
D7971 / 7.2_2.E5
/0.0_2.E5
VALVE PUMP 2
INTERRUPTION PUMP 2
(EXTRA PUMP LIFT)EC
C C
Y60622
X211 XY6012/6062 XY6012/6062
1.5A K1:35 35 21135 1 1 2 2 6012 CHASSIS
D D7971 / 7.2_2.D5 D
/0.0_2.D5
PUMP ATTACHMENT
secuted.
INTERR PUMP ATT
(ACT. PUMP ATT)EC
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets urkoppl. hydr pump DCF300,DCE300 10.4_1
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 Moved from 8.2_2 071520 TKB 071030 6
Wiring interruption hydr. pump A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B776
XB776f XB776f X212
2 2 T 1 1 21213 13 K2:13 Temperature Input
D7971
U /0.0_2.C4
HYDRAULIC OIL TEMPERATURE SENSOR HYDR. OIL TEMP.
7762
B B
M668
X211 XM668f XM668m XM668m XM668f
10A K1:14 14 21114 1 1 1 2 2 2 6682
D7971 M
/0.0_2.D2
MOTOR COOLING FAN HYDR. OIL
COOLING FAN HYDRAULIC OIL
X37202A
X37202
C C
D D
secuted.
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets kyln. hydraul olja DCF300,DCE300 10.6_1
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring cooling hydraulic oil A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
0711 544
MAIN RELAY IGNITION / 11.5_2.C1
/11.5_3.E4
87 30
A K3151 A
W208
21211 582/1:1
/ 11.5_4.A2
F582 2121 582/1:1
1a 1b / 11.5_4.B2
50A /11.5_1.B2 W213 A:1 30 A 1:1 2129 582/1:2
A:1 1:1 / 11.5_4.B2
W214 A:2 A:2 1:2 1:2 21210 582/1:2
/ 11.5_4.B2
W226 B:1 5 A
B:1 2:1
B:2 2:2 2221 582/3:1
/ 11.5_5.D2
C:1 25 A 3:1 2229 582/3:1
2a 2b C:1 3:1 / 11.5_5.D2
F581 C:2 C:2 3:2 3:2 22210 582/3:2
50A / 11.5_5.D2
W223
B W209 A:1 30 A 1:1 0526 581/1:1 D:1 10 A 4:1 W237 582/4:1 B
A:1 1:1 / 11.5_2.A2 D:1 4:1 / 11.5_10.B2
A:2 A:2 1:2 D:2 4:2
B:1 5 A E:1 5 A 5:1 216-246 582/5:1
B:1 2:1 E:1 5:1 / 9.6_5.E2
B:2 2:2 E:2 E:2 5:2 5:2 90012A 582/5:2
3a 3b / 7.2_2.C2
50A W210 C:1 15 A 3:1 2101 581/3:1 F:1 5 A 6:1 2014 582/6:1
C:1 3:1 / 1.0_1.C3 F:1 6:1 / 2.0_1.E2
C:2 C:2 3:2 F:2 F:2 6:2
2105A K3152 2107A
D:1 10 A 4:1 581/4:1 G:1 5 A 7:1 582/7:1
D:1 4:1 / 1.0_1.D3 G:1 7:1 / 1.0_1.E3
D:2 D:2 4:2 4:2 W221 30 87 W222 G:2 7:2
E:1 5 A 5:1 2012 581/5:1 87A H:1 5 A 8:1 2108A 582/8:1
4a 4b E:1 5:1 / 2.0_1.E2 H:1 8:1 / 1.0_1.E3
50A E:2 5:2 /11.5_3.F4 H:2 8:2
W228 377430 RELAY IGNITION
F:1 15A 6:1 581/6:1 /11.5_1.D6 +15
F:1 6:1 / 4.8_1.C2
F:2 6:2
C W214 C
G:1 7:1 F582
G:2 7:2 1 KDU CHASSIS
W304-2-30B H:1 15A 8:1 W304-2-30A 581/8:1 2 NOT USED
H:1 8:1 / 9.6_13.F2 3 KDU OPT. CHASSIS
H:2 8:2
4 OPT.
/11.5_1.D3 +30 5 SWITCHES / SENSORS
6 TRANSMISSION
W207
W206
W211
7 ENGINE
1 CAB 8 ENGINE
2 NOT USED
/11.5_1.C6
3 ENGINE
4 ENGINE
5 TRANSMISSION
6 OPT. COOLING FAN, BRAKES
54/3 7 NOT USED
/ 11.5_6.D2
D 8 Opt. work lights D
/11.5_1.C3
secuted.
GY Batt + W212 CHASSIS
/ 8.2_4.F1 / 11.5_3.E2
37209 CHASSIS
S144 G301 G302 / 7.2_2.E8
2 1 W3 + W2 + W1
X2152A X2152B
12V, 140Ah 12V, 140Ah W219 BU CHASSIS
/ 11.5_5.B7
W5
W220 X37200D
W4
E X37100B E
X37200
X37100
X37200A 0712
M654 G660
B+ X37100C
X37100A X37200
30 31 B D+ X37100 X37100
M G
ALTERNATOR
50 STARTER W X37200B X37200C X0712A
X37200 X37200 X0712
Inkoppling startmotor & generator
F se sida motor 1.0_2. F
Connection starter & alternator
see page engine 1.0_2.
Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets ström DCF300,DCE300 11.5_1
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 Cable GY added. 071520 TKB 071030 6
Wiring power A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A0595
A A
F584
X052m X052f
0526 A0526 A0011 X37A
581/1:1 6 6 A:1 10 A 1:1 584/1:1
/ 11.5_1.B5 A:1 1:1 / 11.5_4.C2
AA2-B1 A:2 A:2 1:2 A0607 584/2:1
/ 9.6_8.A1
B:1 5 A 2:1 A0393 584/2:1 X059f
B:1 2:1 / 9.6_8.B1
B:2 2:2 2:2 A0392 584/2:2 5
/ 9.6_7.A2
A0526A C:1 10 A 3:1 A0594 4
C:1 3:1
AC2-D1 C:2 C:2 3:2 3:2 A0559 584/3:2 3
/ 9.8_1.B2
D:1 10 A 4:1 A0672
D:1 4:1
D:2 4:2
10 A 5:1 A0555 584/5:1
E:1 5:1 / 9.8_1.B2
AE2-F1 E:2 E:2 5:2 5:2 A0707C 584/5:2
/ 7.0_5.B1
B F:1 25 A 6:1 A0634B 584/6:1 X067f B
F:1 6:1 / 9.3_1.D2
A0711B F:2 F:2 6:2 6:2 A0664 584/6:2 2
/ 9.3_7.A1 Dedicated for
15 A 7:1 A0545B 584/7:2 1
G:1 7:1 / 9.6_1.B2
AG2-H1 G:2 G:2 7:2 7:2 A0545C 584/7:2 3 use of customer
/ 9.6_1.D2
H:1 15 A 8:1 A0635B 584/8:1 4
H:1 8:1 / 9.3_2.B2
A0711D H:2 H:2 8:2
/11.5_2.C4 +30/+15 in Cab
F584
X071 1 KCU
544 0711 2 KCU STARTUP A0626A +12V
/ 11.5_1.A4 3 SERVICE
/ 11.5_7.D2
4 OPT. CUSTOMER
C 5 OPT. RADIO C
6 OPT. SEAT HEATER, TURNABLE SEAT.
7 OPT. CONTAINER LIGHT
A0673
8 OPT. AIR SEAT
/11.5_2.C4
F585 A0012 585/1:1 X37B

/ 11.5_4.C2
A0711A A:1 25 A 1:1 A0013 585/1:2
A:1 1:1 / 11.5_4.C2
AA2-B1 A:2 A:2 1:2 1:2 A0014 585/1:2
/ 11.5_4.C2
B:1 10 A 2:1 A0615 585/2:1
B:1 2:1 / 11.5_4.F2
B:2 2:2
D A0711E C:1 15 A 3:1 A0396 585/3:1 D
C:1 3:1 / 9.4_2.C2
AC2-D1 C:2 C:2 3:2 3:2 A0028 585/3:2
/ 9.4_2.D2
secuted.
D:1 5 A 4:1 A0395 585/4:1
D:1 4:1 / 9.4_2.D2
AD2-E1 D:2 D:2 4:2 4:2 A0577 585/4:2
/ 9.9_2.C1
E:1 10 A 5:1 A0593
E:1 5:1
E:2 5:2 5:2 A0671
A0711C F:1 5 A 6:1 A0624 585/6:1
F:1 6:1 / 9.6_8.E1
AF2-G1 F:2 F:2 6:2
901 X901.1f / 11.5_7.B2
G:1 10 A 7:1 585/7:1
G:1 7:1 / 11.5_8.C3
AG2-H1 G:2 G:2 7:2
H:1 10 A 8:1 A0623A 585/8:1
H:1 8:1 / 9.7_3.C2
H:2 8:2
E /11.5_2.F4 +15 in Cab E
F585
1 KCU
2 KIT
3 ECC, FAN
4 ECC, RECIRCULATION
5 SERVICE / CUSTOMER
6 OPT. MAP LIGHT
7 OPT. CONVERTER 12V
8 OPT. COMP. HORN
/11.5_2.E4
F F

Ruta Sign.
Sq.
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 Wire A0577 added.. 071520 TKB 071030 6
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
P 1
B S150 B
STARTER SWITCH 3
58
15
30
19
50
17
130
819
317
750a
515/54
0161 24V D7902/2:1
/ 1.0_1.B1
0162A
584/2:1 0607A
/ 9.6_8.B1
0162 24V D7902/2:2
/ 1.0_1.B1
C C
X060Am X060Af X060m X060f X011

0608 8 8 0608 8 8 1 K11:1 Input
D7901
/0.0_1.C6
SWITCH IGNITION
X058m X058f
6 6 A0586
Cable 0586 is connected to X058f:6 and X058f:7
X058m X058f
when no engine preheater is used. 0586 7 7 A0111
D D
secuted.
W212G CHASSIS
/ 4.8_1.C4
W212C CHASSIS
/ 11.5_6.C2
W212D CHASSIS
/ 11.5_6.C2
W212E CHASSIS
CHASSIS W212 X90044 / 11.5_6.D2
/ 11.5_1.D6 W212F CHASSIS
/ 11.5_6.D2
E K3151 E
X010 X052f X052m
0.5A K10:10 10 A01010 3 3 0523 2 86 85 1 W212A
D7901
/0.0_1.C6 /11.5_1.A2
RELAY K3151 MAIN RELAY IGNITION
K3152
X010 X052f X052m
0.5A K10:16 16 A01016 7 7 0527 86 86 85 85 W212B
D7901
/0.0_1.C6 /11.5_1.C5
RELAY K3152 RELAY IGNITION
F F

Ruta Sign.
Sq.
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 K3151 v K1, K3152 v K4 071520 TKB 071030 6
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A X212 A
582/1:1 21211 11 K2:11 Input
/ 11.5_1.A8 D7971
/0.0_2.B4
Emergency stop
X212 D7971
582/1:1 2121 1 K2:1
/ 11.5_1.A8 Main power
X212 Power supply/Ground X212
582/1:2 2129 9 K2:9 Main power Ground K2:12 12 21212
/ 11.5_1.B8
/ 11.5_1.B8
/0.0_2.B4
B B
X37203A
X37203
X001 D7901
C 584/1:1 A0011 1 K1:1 C
/ 11.5_2.A6 24V Battery
X001 X001
585/1:1 A0012 2 K1:2 K1:5 5 A0015
/ 11.5_2.D6 24V Ignition Ground
585/1:2 A0013 3 K1:3 K1:6 6 A0016
/ 11.5_2.D6 24V Ignition Ground
585/1:2 A0014 4 K1:4
/ 11.5_2.D6 24V Ignition
/0.0_1.A1
X37A
D D
secuted.
D7902
F
E D7902 D7902 E
/11.6_1.B3
Keyb.
Keybord
Ind.
Ind. Cluster
X061f X061m X061Am X061Af X015 X015 X061Af X061Am X061m X061f
585/2:1 A0615 5 5 0615 5 5 0615 1 K4:1 K4:5 5 0616 6 6 0616 6 6 A0616
/ 11.5_2.D6 +
F F
X37A

Ruta Sign.
Sq.
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
X422
42211 11 K2:11 Input
D791
/0.0_4.B4
Emergency stop
X4002D W400 CHASSIS

B / 9.6_2.D8 B
X4001A X4001B X422 D791 X4002C W401 CHASSIS
583/1:1 RD 4221 1 K2:1 / 7.9_2.C5
/ 11.5_6.D7 Main power W402 CHASSIS
X422 / 7.9_1.F7
Power supply/Ground
X4001C 4229 9 K2:9 K2:12 12 42212 X4002B
Main power Ground X4002A
42210 10 K2:10 Main power Ground K2:14 14 42214 BU CHASSIS
/ 11.5_1.E7
/0.0_4.B4
C C
X222
583/5:1 22211 11 K2:11 Input
/ 11.5_6.E7 D7972
/0.0_3.B4
Emergency stop
X222 D7972
582/3:1 2221 1 K2:1
/ 11.5_1.B8 Main power
D Power supply/Ground X222 D
/ 11.5_1.B8
secuted.
/ 11.5_1.B8
/0.0_3.B4
X37208
E E
F F

Ruta Sign.
Sq.
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
S250
X008
24V D7901/8:16 00816K 1 2 0084 4 K8:4 Input
/ 8.2_1.B2 D7901
/0.0_1.D4
OPERATING SWITCH SW. OPERATING POWER
A A
K3002
XK3002 XK3002
0525C 86 85 86 85
/7.7_1.C3
TILT IN / OUT
K3007
XK3007 XK3007
0525B 86 85 86 85
B /7.2_1.C3
B
LIFT / LOWER
K30092
X010 X052f X052m
0.5A K10:12 12 A01012 5 5 0525 X90045 0525A 2 86 85 1
D7901
/0.0_1.C6 /11.5_6.D3
RELAY K30092,K3002,K3007 RELAY OPERATING SWITCH
K30091
X010 X052f X052m
0.5A K10:11 11 A01011 4 4 0524 2 86 85 1
D7901
/0.0_1.C6 /11.5_6.D2
C RELAY K30091 RELAY OPERATING SWITCH C
CHASSIS W212C
/ 11.5_3.D7
CHASSIS W212D
/ 11.5_3.E7
CHASSIS W212E
/ 11.5_3.E7
CHASSIS W212F
/ 11.5_3.E7
X2151A
RELAY OPERATING SWITCH RELAY OPERATING SWITCH 1681 RD 583/1:1
/11.5_6.C4 /11.5_6.C4 F583 / 11.5_5.B2
D D
54/3 W211 W215 W216A A:1 1:1 W227 X168 X2151B
25 A
/ 11.5_1.D3 30 87 30 87 A:1 1:1
secuted.
A:2 A:2 1:2
K30091 K30092
B:1 5 A
B:1 2:1
B:2 2:2
W216B 5 A 3:1 2024 583/3:1
C:1 3:1 / 7.0_5.D2
C:2 C:2 3:2
D:1 5 A
D:1 4:1
D:2 4:2
E:1 5 A 5:1 22211 583/5:1
E:1 5:1 / 11.5_5.C2
E:2 5:2
F:1 6:1
E F:2 6:2 E
G:1 7:1
G:2 7:2 X051m X051f X011
W218 5 A 8:1 0511 1 1 A01113 13 K11:13 Input
H:1 8:1 D7901
H:2 8:2 /0.0_1.D6
/11.5_6.F5 +15E FEEDBACK K2
F583
1 KDU ATTACHMENT
2 NOT USED
3 FORK ATTACHMENT
4 NOT USED
5 KDU OPT. CHASSIS
F 6 NOT USED F
7 NOT USED
8 FEEDBACK K30091
/11.5_6.E4

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets ström manöverbrytare DCF300,DCE300 11.5_6
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 S250 Ä. 071520 TKB 071030 6
Wiring power operating switch A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
X901.3f W14B
24V COM
X901.2f W14A
GND
X901.4f
585/7:1
/ 11.5_2.E6 12V
24V 12V
A901 X37C
B B
X37C
X055f X055m X905f

A0558 8 8 0558 2
A0556 6 6 0556 1 Com. Radio 12V
C C
OPTION ADAPTER
X062f X062m XE804f XE804m XE804Af

A0626 6 6 0626 1 1 804A1B 1
Cig. 12V
2 2 804A2B 2
+12V A0626A
/ 11.5_2.C8 XA9091f
804A1A 1 +12V
/ 9.8_2.A2
D 804A2A 2 CHASSIS D
/ 9.8_2.A2
secuted.
W03
E E
X37D
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets 24/12V DCF300,DCE300 11.5_7
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring 24/12V A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
X901.1m X901.2m X901.2f

585/7:1 W14A
/ 11.5_2.E6
X901.3f
C W14B X37C C
X072f
BK 2
GY 1 24V
D D
secuted.
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets 24V uttag DCF300,DCE300 11.5_8
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring 24V contact A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
X221 X240f
10A K1:14 14 22114 1
D7972
/0.0_3.D2
OPT.
X240f
B 4 W235D CHASSIS B
/ 11.5_11.A8
X221 X240f
6A K1:28 28 22128 2
D7972
/0.0_3.D5
OPT.
C X221 X240f C
Analog In 05V K1:24 24 22124 3
D7972
/0.0_3.C5
OPT.
D D
secuted.
X221 X249f X249f
6A K1:42 42 22142 1 D7972/1:42 CHASSIS 2 W235F CHASSIS
D7972 / 9.6_10.D2 / 9.6_10.D7 / 11.5_11.B8
/0.0_3.D5
OPT.
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets option grund kraft DCF300,DCE300 11.5_9
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 X249 T, X249.1 & 2 V X240.3 & 4 071520 TKB 071030 6
Wiring option base power A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
X221 X242f X242f X221

Analog Ref 5V K1:8 8 2218 5 D7972/1:41 1 22141 41 K1:41 Analog In 05V
D7972 / 7.9_3.A7 D7972
/0.0_3.D2 /0.0_3.D5
OPT. OPT.
X221 X242f X242f X221

0V Ref K1:6 6 2216 6 2 22121 21 K1:21 Analog In 05V
D7972 D7972
/0.0_3.C2 /0.0_3.C5
OPT. OPT.
B B
X242f X242f X221

582/4:1 W237 7 582/4:1 D7972/1:22 3 22122 22 K1:22 Analog In 05V
/ 11.5_1.B8 / 7.9_3.A2 / 7.9_3.B7 D7972
/0.0_3.C5
OPT.
X242f X221
D7972/1:23 4 22123 23 K1:23 Analog In 05V
C / 7.9_3.B7 D7972 C
/0.0_3.C5
OPT.
X242f
CHASSIS 8 W235E CHASSIS
/ 7.9_3.A7 / 11.5_11.A8
D D
secuted.
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets option grund DCF300,DCE300 11.5_10
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring option base A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
W235D CHASSIS
/ 11.5_9.B7
W235E CHASSIS
/ 11.5_10.D7
W235F CHASSIS
/ 11.5_9.D7
B B
X221 X241f X241f
Dig In / 1.5A K1:11 11 22111 2 24V D7972/1:11 CHASSIS 1 W235B X90035 W235A
D7972 / 9.9_1.B2 / 9.9_1.B7
/0.0_3.D2
OPT.
X37215
X221 X241f
Dig In / 1.5A K1:12 12 22112 3 24V D7972/1:12
D7972 / 9.9_1.D2
/0.0_3.D2
C C
OPT.
X221 X241f X241f

Dig In / 1.5A K1:26 26 22126 6 CHASSIS 4 W235C
D7972 / 9.9_1.D7
/0.0_3.C5
OPT.
D D
secuted.
X221 X241f
Dig In / 1.5A K1:40 40 22140 5
D7972
/0.0_3.D5
OPT.
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets option grund DCF300,DCE300 11.5_11
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring option base A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
R8202 D795
1 2 X020 X020 X060Am X060Af X060m X060f X051f X051m
6 K1:6 CAN 2 K1:13 13 30 0605 5 5 30 0605 5 5 A0512A 30 2 2
+ L+
0606 0606 A0513A
WH
GY
5 K1:5 CAN K1:12 12 6 6 6 6 3 3
L
A K1:4 K1:8 8 0604 4 4 0604 4 4 A
Shield +
GY
X020 RS232
KID_TX 30 1823 3 K1:3 K1:11 11 30 0601A 1 1 30 0601 1 1
/ 9.8_2.B2 TX R+
1822 CAN 0602A 0602
WH
KID_RX 2 K1:2 RX R K1:10 10 2 2 2 2
/ 9.8_2.B2
KID_GND 1825 1 K1:1 K1:7 7 0603 3 3 0603 3 3
/ 9.8_2.B2 GND +
GY
X020 X061Af X061Am X061m X061f
7902/1:14 02014 14 K1:14 BUZZER 0V REF K1:9 9 0613 3 3 0613 3 3
/ 9.7_1.E7
WH
KID
0152
0156
6
5
4
3
2
1
X203m
A0513B
A0512B
D7902
30
30
A0613
6
5
4
3
B /11.5_4.E4 B
X203f
X015 X015
2 K4:2 K4:7 7 0601B
+ + X37A
6 K4:6 CAN CAN K4:8 8 0602B

2034
0521 30 X059f
30
2 30 30 0513
0522 K4:3 Shield Shield K4:4 1 0512
2033
30
X052m X052f
1 1 30 A0481B X048 1 30 A0131
2033 CAN_J1939_+
/ 1.0_1.C3 A B
2036
X052m X052f
30
2034 CAN_J1939_
/ 1.0_1.D3 2 2 30 A0482B X048 2 30 A0132
C C
2035 CAN_J1939_+ A B A0135 30
2035
/ 2.0_1.D2
30
X049m A0134
2036 CAN_J1939_
/ 2.0_1.D2 A 30 A0481A
R8201
B A0482A 1 2
X013 KCU X013 X050

1 K13:1 TX
K13:10 10 A01310 3
+
2 K13:2 CAN J1939 RS232 K13:11 11 A01311 2
RX
No extra KDU => connect X209Af and 209Am K13:3 K13:12 12 A01312 5

Shield Ground
X013
/ 11.6_2A.C7 4 K13:4
L+
/ 11.6_2B.B7 X209Am 5 K13:5 CAN
CAN+ 4 0514 L
D / 11.6_2C.B7 K13:6 D
Shield
X051m X051f X013 D7901
secuted.
/ 11.6_2A.C7 30 4 4 30 A0137 7 K13:7 /0.0_1.E6
/ 11.6_2B.B7 R+
CAN 3 0515 5 5 A0138 8 K13:8 CAN
/ 11.6_2C.B7 R
K13:9
Shield
RED+2 2 0519A X011
/ 11.6_2C.B7 A0117 CANBUS
6 6 7 K11:7
Power 1
8 8 A0118A 8 K11:8
Power 1
/ 11.6_2A.C7 7 7 A0119 9 K11:9
/ 11.6_2B.B7 Power 2
RED+1 1 0518A 9 9 A01110A 10 K11:10
/ 11.6_2C.B7 Power 2
E A0118B E
A01110B X212
0513 5
R
0512 4 K2:5 CAN
X209Af R+
K2:4 CANBUS
RED+1 1 0518B 0517 0517 8
/ 11.6_2C.E7 +
K2:8
/ 11.6_2A.D7 0516 0516 7
+ /0.0_2.B4
/ 11.6_2B.C7 0519B 30 2123 K2:7
RED+2 2 3 D7971
/ 11.6_2C.E7 L
2122 2 K2:3 CAN
L+
/ 11.6_2A.D7 K2:2
/ 11.6_2B.C7 2123
CAN 3
/ 11.6_2C.F7
F F
/ 11.6_2A.D7
/ 11.6_2B.C7 2122
CAN+ 4
/ 11.6_2C.E7
Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets CANBUS grund DCF300,DCE300 11.6_1
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring CANBUS base A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
X209Bf
30 4 CAN+
/ 11.6_1.D2
3 CAN
/ 11.6_1.D2
1 RED+1
C
Opt. chassi / 11.6_1.E2 C
X222
K2:2 2 2222
L+
CAN K2:3 3 2223
D7972 L
K2:7 7 2227
+
X209Bm
K2:8 8 2228 2 RED+2
CANBUS + / 11.6_1.F2
K2:4 4 2224 30 4 CAN+
R+ / 11.6_1.F2
CAN K2:5 5 2225 3 CAN
R / 11.6_1.F2
CAN Shield
K2:6
D D
secuted.
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets CANBUS KDU opt. DCF300,DCE300 11.6_2A
CJS 050128 A47137.0100
Name
R
E³ DRAWING
Wiring CANBUS KDU opt. chassi A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B X209Cf B
4 CAN+
/ 11.6_1.D2
3 CAN
/ 11.6_1.D2
1 RED+1
/ 11.6_1.E2
Opt. attachment
X422 X401Am X401Af
K2:2 2 4222 30 A A GN 30
L+
CAN K2:3 3 4223 B B YE
C D791 L C
K2:7 7 4227 C C GY
/0.0_4.B4 +
X401Bf X401Bm X209Cm
K2:8 8 4228 C C OG 2 RED+2
+ / 11.6_1.F2
CANBUS K2:4 4 4224 30 A A BN 30 4 CAN+
R+ / 11.6_1.F2
CAN K2:5 5 4225 B B WH 3 CAN
R / 11.6_1.F2
D D
secuted.
E E
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets CANBUS KDU opt. DCF300,DCE300 11.6_2B
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 GY changed with OG 071520 TKB 071030 6
Wiring CANBUS KDU opt. attachment A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
Opt. attachment
X422 X401Am X401Af X209Cf
K2:2 2 30 1 4222 A A GN 30 4 CAN+
L+ / 11.6_1.D2
CAN K2:3 3 2 4223 B B YE 3 CAN
D791 L / 11.6_1.D2
K2:7 7 3 4227 C C GY 1 RED+1
+ / 11.6_1.E2
X401Bf X401Bm 2 RED+2
/ 11.6_1.E2
K2:8 8 3 4228 C C
+
CANBUS K2:4 4 30 1 4224 A A
R+
B CAN K2:5 5 2 4225 B B B
R
BN
WH
OG
2092
C C
30
2091
D D
4
3
2
1
1
2
secuted.
X209Cm
X214m
1
1
2
2
4
3
X214f
X209Bf
2142
Opt. chassis
X222
2222 30
2141
E K2:2 2 E
L+
CAN K2:3 3 2223
D7972 L X209Bm
K2:7 7 2227 1 RED+1
/0.0_3.B4 + / 11.6_1.E2
K2:8 8 2228 2 RED+2

+ / 11.6_1.F2
CANBUS K2:4 4 2224 30 4 CAN+
R+ / 11.6_1.F2
CAN K2:5 5 2225 3 CAN
R / 11.6_1.F2
F F

Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets CANBUS KDU opt. DCF300,DCE300 11.6_2C
CJS 050128 A47137.0100
Name
R
E³ DRAWING
1 GY changed with OG 071520 TKB 071030 6
Wiring CANBUS KDU opt. chassi + attach A49226.0100 17
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
BU BU
BU BU
A A
-K1 -K3 -K4 -K5 -K6 -K7
85 85 86 86 85 85 86 86 85 85 86 86 85 85 86 86 85 85 86 86 85 85 86 86
BU
BU
BU
30 30 87 87 30 30 87 87 30 30 87 87 30 30 87 30 30 87 87 30 30 87 87
87A 87A 87A 87A 87a 87A 87A
ALIGNMENT TWISLOCKS OPEN TWISTLOCKS LOCKED END POSITION DAMPING LENGTH ADJUSTMENT 20 - 40 TWISTLOCK VALVE
10
10
B B
5 9
1
BU 13
14
7
8
11
12
BU 20
22
23
CHASSIS BU
/5.A7 17
1 -XK8 -XK8-30
14 30 1
C C
GY
-XK8 -XK8-87a
19 87a 1
-X100 1 1 2 2 5 7 8 9 10 11 12 13 14 17 19 20 22 23
RD +24V
-X200 1 1 /4.E2
TWISTLOCK YE TW._LOCKED
2 2 /4.E2
20' - 40' GY TW._OPEN
3 3 /4.E2
GND BK ALIGNMENT
D 4 4 /4.E2 D
24V

secuted.

unauthorized purpose. Contravention will be pro-
5 5
ALIGNMENT YE./.GN CHASSIS
/2.D2
6 6
TWISTLOCKS OPEN 1 DAMPING
7 7 /2.D2
TWISTLOCKS LOCKED
8 8 2 +24V
30' - 35' /2.D2
+24V_VIA_KNAPP
/5.D7
2 CHASSIS
/2.D2
CHASSIS
/5.E7
8 TW._LOCKED
E /2.E2 E
DAMPING GY
/5.E7
6 TW._OPEN
/2.E2
CHASSIS BU
/3.C7
1 +24V
/2.E2
TW. RD
/3.A2
4 ALIGNMENT
/2.E2
SPREADING YE
/3.B2
1 +24V


Den får ej heller delgivas annan eller annars obe-
/2.E2
DAMPING GY
/3.C2
F 2 CHASSIS F
/2.F2

Nr Ändring Ändring nr Datum Sign. Datum/Date
Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn CJS 021206 1 5
+ATTACHMENT Krets aggregat topplyft 20-40 DCD370-
R
H.Grp: Name Ritn.nr./ Drawing No. Utgåva/Issue
1 Nyupplägg / New design 021756 CJS 021206 Konstr/Design 6
E³ DRAWING
T=Tillk/Added U=Utgår/Deleted V=Var/Was Godk/Appr LME 021209 Klass/Class Wiring diagram attachment toplift 20-40 A44659.0100 01
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
KONTAKT ECONOSEAL, SERIE E KONTAKT ECONOSEAL, SERIE E

CONTACT ECONOSEAL, SERIE E CONTACT ECONOSEAL, SERIE E
-X7202Rf -X7202Rm
3 2 2 BN
-X7202Lm -X7202Lf -B7202R
BN 2 2 3 4 1 1 BK
A -B7202L A
BK 1 1 4 BU 3 3 ALIGNMENT RIGHT FRONT
3 3 BU BU
ALIGNMENT LEFT FRONT
BU
-X7203Rf -X7203Rm
9 2 2 BN
-X7203Lm -X7203Lf -B7203R
BN 2 2 1 7 1 1 BK
-B7203L
BK 1 1 9 BU 3 3 ALIGNMENT RIGHT REAR
3 3 BU BU
ALIGNMENT LEFT REAR
BU
-X7204Rf -X7204Rm
BK 2 2 BN
-X7204Lm -X7204Lf -B7204R
BN 2 2 5 5 1 1 BK
B -B7204L B
BK 1 1 6 BU 3 3 UNLOCKED TWISTLOCK RIGHT
3 3 BU BU
UNLOCKED TWISTLOCK LEFT
BU
-X7205Rf -X7205Rm
BK 2 2 BN
-X7205Lm -X7205Lf -B7205R
BN 2 2 7 6 1 1 BK
-B7205L
BK 1 1 8 BU 3 3 LOCKED TWISTLOCK RIGHT
3 3 BU BU
LOCKED TWISTLOCK LEFT
BU
-XSP4
C C
-X769m -X769f
BN 2 2
-B769
BK 1 1
END POSITION DAMPING 3 3
BU
-XSP2
-XSP3
CHASSIS YE./.GN
/1.D7
D DAMPING 1
/1.D7 D

secuted.

+24V 2
/1.E7
-X100 3 4 6 15 16
CHASSIS 2
/1.E7
TW._LOCKED 8
/1.E7
TW._OPEN 6
/1.E7
+24V 1
E /1.E7 E
ALIGNMENT 4
/1.F7
+24V 1
/1.F7
CHASSIS 2
/1.F7


F F

Ruta Sign.
Sq.
R
E³ DRAWING
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-Y6044
TW. RD 1 1 2 2 BU
/1.E2
SOLENOID VALVE TWISTLOCK
-Y6046
B B
SPREADING YE 1 1 2 2 BU
/1.F2
SOLENOID VALVE SPREADING
CHASSIS
/1.E2
-XSP5
-Y6046-2
C C
DAMPING GY 1 1 2 2 BU
/1.F2
SOLENOID VALVE SPREADING DAMPING
-Y6046-3
D D
30-35_Stop BK 1 1 2 2 BU
/5.D7

secuted.

SOLENOID VALVE 30-35 STOP
OPTION
E E


F F

Ruta Sign.
Sq.
R
E³ DRAWING
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-E563 -E564 -E562

B B
1 1 2 1 1 1 2 1 1 1 2 1
TWISTLOCKS LOCKED ALIGNMENT TWISTLOCKS OPEN
RD
C C
RD RD
-XSP1
D D

secuted.

+24V RD
/1.D7
TW._LOCKED YE
E /1.D7 E
TW._OPEN GY
/1.D7
ALIGNMENT BK
/1.D7


F F

Ruta Sign.
Sq.
R
E³ DRAWING
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
Option 30-35' stop
BU CHASSIS
/1.C2
-K8
85 85 86 86
B B
30 87 87
87A
Bygel mellan 30 - 87a ersatt

av relä vid 30-35' stopp.
24
18
Jumper between 30 - 87a replaced
by relay at 30-35' stop.
C C
-X100 18 21 24
BK BK 30-35_Stop
/3.D2
-X777-1m -X777-1f
BN 2 2 RD RD 8 +24V_VIA_KNAPP
-B777-1 /1.E2
BK 1 1 -XSP6
D 3 3 BU
30-35 STOP D
BU

secuted.

-X777-2m -X777-2f
BN 2 2 RD
-B777-2
BK 1 1
3 3 BU BU CHASSIS
30-35 STOP DAMPING /1.E2
BU -XSP7
E E
GY DAMPING
/1.E2


F F

Ruta Sign.
Sq.
R
E³ DRAWING
1 2 3 4 5 6 7 8
E Schema - Komponentförteckning / E Schematics - List of Components 1
Komponentförteckning / List of Components

Number Categ. Svenska English
30 G Batteri Battery
32 A Kretskort elcentral Printed circuit board, Junction box
37 X Terminal stomanslutning Earthing terminal on chassis
39 X Terminal minusanslutning Terminal, negative terminal
51 F Säkringshållare 1-polig Fuse holder, 1-pole
62 F Batterihandske 2-polig Battery connector, 2-pole
64 F Batterihandske 4-polig Battery connector, 4-pole
72 X Stickuttag 2-polig Outlet, 2-pole
77 X Stickuttag 7-polig Outlet, 7-pole
78 X Stickuttag extra 7-polig Outlet, extra, 7-pole
100 S Strömställare ljus Switch, light
101 S Strömställare omk hel/halvljus Switch, main/dipped beam
102 S Strömställare dimljus Switch, fog light
103 S Strömställare fjärrljus Switch, distance light
104 S Strömställare lastljus Switch, mast lights
105 S Strömställare arbetsljus Switch, working lights
106 S Strömställare containerljus Switch, container light
107 S Strömställare park broms Switch, parking brake
108 S Strömställare centr smörjning Switch, central lubricator
109 S Strömställare varningsljus Switch, hazard lights
110 S Strömställare rot varningsljus Switch, rotating hazard beacon
111 S Strömställare fönsterhiss Switch, window regulator
112 S Strömställare kylanläggning (AC) Switch, air conditioner (AC)
113 S Strömställare styrning alt Switch, alternative steering
114 S Strömställare läsbelysning Switch, reading light
115 S Strömställare instr belysning Switch, instrument illumination
116 S Strömställare innerbelysning Switch, interior lighting
117 S Strömställare värme Switch, heating
118 S Strömställare fläktm värme Switch, heater fan
119 S Strömställare vindrutetorkare Switch, wiper
120 S Strömställare spolare Switch, washer
121 S Strömställare blackout Switch, blackout
122 S Strömställare nöd hydraulpump Switch, emergency hydraulic pump
123 S Strömställare backspegel Switch, observation mirror
124 S Strömställare kallstart Switch, cold start
125 S Strömställare avgasbroms Switch, exhaust brake
126 S Strömställare diff spärr/broms Switch, diff. Block
127 S Strömställare värmesystem diesel Switch, heating system diesel
128 S Strömställare kraftuttag sida Switch, power take off side
129 S Strömställare kraftuttag bak Switch, power take off rear
130 S Strömställare hög/lågväxel Switch, high/low gear
131 S Strömställare färdväljare fram Switch, gear selector forward
132 S Strömställare färdväljare bak Switch, gear selector rear
135 S Strömställare växelväljare Switch, gear shift
136 S Strömställare framhjuls styrning Switch, forward wheel steering
137 S Strömställare 4-hjuls styrning Switch, 4-wheel steering
138 S Strömställare crab styrning Switch, crab steering
Verkstadsmanual / Workshop Manual DCF


139 S Strömställare defroster Switch, defroster
141 S Strömställare Stegbelysning Switch, Steplight
142 S Strömställare fot Switch, foot
143 S Strömställare sitsvärme Switch, seat heater
144 Q Batterifrånskiljare Battery disconnecting switch
145 S Strömställare AT-regulator Switch, AT-regulator
147 S Strömställare körvisare Switch, direction indicators
149 S Strömställare signalhorn Switch, horn
150 S Strömställare startlås/ellas Switch, main key switch
152 S Strömställare intervalltorkare Switch, intermittent wiper
156 S Strömställare kupevärmare Switch, cab heating
157 S Strömställare stoltilt Switch, seat tilt
158 S Strömställare dimbakljus Switch, rear fog light
159 S Strömställare extra fram/back väljare Switch, extra direction selector
160 S Strömställare komb fram/back Switch, combi-forward/reverse
161 S Strömställare komb signal, ljus hel/halv Switch, combi-horn, light main/dipped beam,
spol,torkare m intervall körvisare washer, wiper (intermittent), direction
indicator
162 S Strömställare komb signal ljus hel/halv, Switch, combi horn, light main/dipped beam,
spol, torkare m 2 int, fram/bacK washer, wiper w 2int., forward/revers
163 S Strömställare start på 2-an Switch, start 2nd gear

165 S Strömställare stolvärme Switch, seat heater
166 S Strömställare låsning vändskiva Switch, interlocking of turntable
167 S Strömställare luftfjädring Switch, pneumatic springing
168 S Strömställare låsn stol Switch, interlocking of seat
169 S Strömställare stolsvändning Switch, reversible seat
170 S Strömställare förångare (LPG) Switch, evaporator (LPG)
171 S Strömställare v-skiva upp/ner Switch, fifth wheel up/down
172 S Strömställare v-skiva fr/back Switch, fifth wheel forward/reverse
173 S Strömställare v-skiva skevning Switch, fifth wheel, levelling
174 S Strömställare,utskjut Switch, projecting
175 S Strömställare hyttlyft upp Switch, cab hoist up
176 S Strömställare hyttlyft ner Switch, cab hoist down
177 S Strömställare hyttskjutning Switch, cab movement
178 S Strömställare nollställning Switch, reset
179 S Strömställare Aut/man växling Switch Aut/man gearshifting
180 S Strömställare fyrhjulsdrift Switch, 4-WD
190 S Strömställare klimatanläggning Switch, air conditioner
191 S Strömställare recirkulation Switch, re-circulation
192 S Strömställare vattenavskiljare
195 S Strömställare joy-stick X Switch, joy-stick X
196 S Strömställare joy-stick X+Y Switch, joy-stick X+Y
197 S Strömställare längs/tvärskörning Switch, length/sideways driwing
198 S Strömställare flytläge skevning Switch, equalizing fifth wheel
199 S Strömställare option Switch, option
200 S Brytkontakt lampa park broms Contact, breaking,warning lamp,parking
brake
201 S Brytkontakt lampa färdbroms Contact, breaking, warning lamp, brake
202 S Brytkontakt lampa oljetryck motor Contact, breaking, warning lamp, oil
pressure engine
204 S Brytkontakt tryck ackumulator Contact, breaking, pressure accumulatortank
205 S Brytkontakt innerbelysning Contact, breaking, interior lighting


206 S Brytkontakt handskfack belysning Contact, breaking, glove
207 S Slutkontakt diff spärr Contact, making, diff. interlock
208 S Slutkontakt lampa temperatur spolkrets Contact, making, warning lamp temperature
bromsar brake
214 S Slutkontakt överväxel Contact, making, over drive
215 S Slutkontakt temp motor Contact, making, temperature engine
216 S Slutkontakt bromsljus Contact, making, brake lights
217 S Slutkontakt backljus Contact, making, reversing light
218 S Slutkontakt AT-regulator Contact, making, AT-control
219 S Slutkontakt lampa luftfilter Contact, making, indicating light air filter
220 S Brytkontakt drivning Contact, breaking, drive cut off
221 S Slutkontakt temp växellåda Contact, making, temperature gear box
222 S Slutkontakt lampa temp moment - Contact, making, warning lamp temperature
förstärkare torque amplifier.
223 S Släpkontakt signal Contact, brush, horn
224 S Slutkontakt insprutningspump Contact, making, injection pump
225 S Brytkontakt säkerhetsbälte Contact, breaking, seat belt
228 S Slutkontakt hyttlåsning Contact, making, cab locking
229 S Slutkontakt stolslåsning Contact, making, seat locking
230 S Brytkontakt stol Contact, breaking, seat
231 S Slutkontakt fotkontroll stolvändning Contact, making, seat rotation, foot switch
232 S Brytkontakt lampa luftanslutning släp Contact, breaking, warning lamp air
connection
233 S Slutkontakt lampa låsning vändskiva Contact, warning, interlocking of turntable
235 S Slutkontakt sidoskjutning stol Contact, making, side shifting of seat
236 S Slutkontakt vattennivå Contact, water level
239 S Brytkontakt termisk Contact, breaking, thermic
240 S Slutkontakt termisk Contact, making, thermic
241 S Brytkontakt lampa luftmatning släp Contact, breaking, warning lamp air supply to
trailer
242 S Slutkontakt lampa oljetryck v-låda Contact, making, warning lamp, oil pressure
gear box
243 S Brytkontakt tryck kylmedia AC Contact, breaking, coolant pressure (air
condition)
244 S Slutkontakt hydraulik aktiverad Contact, making, hydraulics
245 S Slutkontakt hydraultryck styrning Contact, making, hydraulic pressure control
246 S Slutkontakt tryck kylmedia Contact, pressure refrigerant

250 S Manöverbrytare Operating Switch
251 S Slutkontakt vändbar förarstol Contact, making, VBFS
260 S Slutkontakt lyft steg 1 Contact, making, hoist step 1
261 S Slutkontakt lyft steg 2 Contact, making, hoist step 2
262 S Slutkontakt tilt Contact, making, tilting
263 S Slutkontakt gaffelspridning Contact, making, fork positioning
264 S Slutkontakt sidoföring Contact, making, sideshift
265 S Slutkontakt stativ in/ut Contact, making, lifting mast in-out
266 S Brytkontakt hyttdörr Contact, breaking cab door
267 S Slutkontakt bromstryck Contact, making, brake pressure
268 S Slutkontakt kompressor Contact, making, Compressor
269 S Slutkontakt sax inne Contact, making extender in
270 S Slutkontakt överlastskydd Contact, making, overload protection
299 S Slut/brytkontakt option Contact, making/braking option
300 K Relä hel/halvljus Relay, main/dipped beam


301 K Relä dimljus Relay, fog light
302 K Relä fjärrljus Relay, distance light
303 K Relä lastljus Relay, mast light
304 K Relä arbetsljus Relay, working light
305 K Relä backljus Relay, reversing light
306 K Relä helljus Relay, main beam
307 K Relä halvljus Relay, dipped beam
308 K Relä bromsljus Relay, brake light
309 K Relä parkeringsbroms Relay, parking light
310 K Relä körvisare vä Relay, direction indicator left
311 K Relä körvisare hö Relay, direction indicator right
312 K Relä startelement Relay,element preheater
313 K Relä vändbar förarstol Relay, rotating driver´s seat (VBFS)
314 K Relä parkeringsbroms Relay, parking brake
315 K Relä tändningslås Relay, ignition key
316 K Relä torkare Relay, wiper
317 K Relä strålkastartorkare Relay, roading lights wiper
318 K Relä AT-regulator Relay, AT-regulator
319 K Relä varningsblinkers Relay, hazard blinkers
320 K Relä elektrisk stopp Relay, electical stop
321 K Relä intervalltorkare Relay, intermittent wiper
322 K Relä kylvätskenivå Relay, coolant level
323 K Relä blinkers Relay, blinkers
324 K Relä rangespärr Relay, range interlock
325 K Relä blinkande bromsljus (back) Relay, flashing brake lights (reversing)
326 K Relä blinkande bromsljus (runt) Relay, flashing hazard brake lights
327 K Relä växel neutral Relay, gear neutral
328 K Relä växelskifte Relay, gear shift
329 K Relä växel hög/låg Relay, high/low gear
330 K Relä startspärr Relay, start interlock
331 K Relä drivning fram Relay, forward driving
332 K Relä drivning bak Relay, reversing driving
333 K Tidrelä förvärmning Time relay, automatically preheating
334 K Relä frikoppling/drivbrytning Relay, free wheel/drive disconnection
335 K Relä växelventil 1:a (diesel, gas) Relay, gear change valve 1-gear
(diesel,LPG)
336 K Relä växelventil 2:a (diesel, gas) Relay, gear change valve 2-gear
(diesel,LPG)
337 K Relä drivriktning motor Relay, motor drive direction
338 K Relä kylfläkt drivmotor Relay, cooling fan drive motor
339 K Relä kylfläkt elskåp Relay, cooling fan electrical box
340 K Tidrelä fördröjt tillslag Time relay, start delay
341 K Tidrelä fördröjt frånslag Time relay, stop delay
342 K Relä drivning 2/4 hjul Relay, switching 2/4 WD
343 K Relä dimbakljus Relay, fog light rear
344 K Relä momentförstärkare Relay, torque amplifier
345 K Relä låsning vändskiva Relay, interlocking of turntable
346 K Relä frikoppling stollåsning Relay, releasing of seat interlocking
347 K Relä stolvändning/ljussignal Relay, multifunction, seat rotation/light signal
348 K Relä fläktmotor värmare Relay, fan heating

349 K Relä fartreglage Relay, speed control
350 K Relä pumpkontaktor/pumpkontroll Relay, pump contactor/pump control
351 K Relä hyttlyft upp Relay, cab hoist up


352 K Relä hyttlyft ner Relay, cab hoist down
353 K Relä säkerhetsslinga Relay, safety loop
354 K Relä styrsystem Relay, signal control system
355 K Relä sensorstyrning Relay, sensor control
356 K Skiftrelä längskörning/tvärskörning Shift relay, length/sideways driving
357 K Relä roterande varningsljus Relay, hazard beacon
358 K Relä komressor luft Relay, compressor air
359 K Relä Hydrauloljekylare Relay hydraulic oil cooler
360 K Relä startsolenoid Relay, starting solenoid
361 K Relä kompressor AC Relay, compressor air conditione
362 K Relä vattenventil AC Relay, water valve air conditioner
363 K Relä kondensor AC Relay, condenser air conditione
364 K Relä stolsbrytare Relay seat switch
365 K Relä fönsterhiss upp Relay, electrical screen elevator up
366 K Relä fönsterhiss ner Relay, electrical screen elevator down
367 K Relä styrning Relay, steerin
368 K Relä lågt bromstryck Relay, low brake pressure
369 K Relä centralsmörjning Relay, central lubrication
370 K Relä centralsmörjning, aggregat Relay, central lubrication, attatchment
371 K Relä lyfthöjd Relay, liftheight
372 K Relä blinkande varn.ljus, höjdbegränsn. Relay, flashing beacon, lifting height limiter
373 K Relä bakljus Relay light

375 K Huvudkontaktor reglersystem Main contactor, operating control
376 K Kontaktor fram reglersystem Contactor, forward operating control
377 K Kontaktor bak reglersystem Contactor, reversing operating control
378 K Kontaktor by-pass Contactor, ¿by-pass¿ operating control/
reglersystem/Fältförsvagning Field weakening
379 K Kontaktor pumpmotor Contactor, pump motor
380 K Kontaktor Contactor
381 K Kontaktor återladdning Contactor, recharging
382 K Relä, förbikoppling säkerhetssystem Relay, by-pass safety system
383 K Relä, Stolsvärme Relay, heated seat
384 K Relä vattenseparator Relay, waterseparator
385 K Relä bränslepump insprutning Relay, fuel injection pump
386 K Relä, hög motortemperatur. Relay, high motor temperature
387 K Relä alternativ gaspedal Relay alternative throttle pedal
388 K Relä, Extra färdriktningsväljare Relay, Extra direction selector
389 K Relä, Pausvärme Relay, Paus heat
399 K Relä option Relay, option
400 E G-lampa vä fram Light bulb, roading light left hand front
400 E G-lampa hö fram Light bulb, roading light right hand rear
401 E G-lampa vä bak Light bulb, roading light left hand front
401 E G-lampa hö bak Light bulb, roading light right hand rear
402 E G-lampa fjärrljus Light bulb, distance light
403 E G-lampa lastljus Light bulb, mast light
404 E G-lampa arbetsljus Light bulb, working light
405 E G-lampa backljus Light bulb, rear light
406 E G-lampa cont belysning vänster Container light left-hand
406 E G-lampa cont belysning höger Container light right-hand
408 E G-lampa park ljus vä fram Light bulb, parking light, left-hand forward
408 E G-lampa park ljus hö fram Light bulb, parking light, right-hand forward
410 H G-lampa broms ljus vä fram Light bulb, brake light, left-hand forward


410 H G-lampa broms ljus hö fram Light bulb, brake light, right-hand forward
411 H G-lampa broms ljus vä bak Light bulb, brake light, left-hand rear
411 H G-lampa broms ljus hö bak Light bulb, brake light, right-hand rear
412 H G-lampa bak ljus vä bak Light bulb, rear light, left-hand rear
412 H G-lampa bak ljus hö bak Light bulb, rear light right-hand rear
413 H G-lampa bak ljus vä fram (VBFS) Light bulb, rear light, left-hand forward
(VBFS)
413 H G-lampa bak ljus hö fram (VBFS) Light bulb, rear light,right-hand forward
(VBFS)
416 H G-lampa sidomarkering vä fram Light bulb, side position light, left-hand
forward
416 H G-lampa sidomarkering vä bak Light bulb, side position light, left-hand rear
417 H G-lampa sidomarkering hö fram Light bulb, side position light, right -hand
forward
417 H G-lampa sidomarkering hö bak Light bulb, side position light, right-hand rear
420 H G-lampa positionsljus vänster Light bulb, position light, left-hand

421 H G-lampa positionsljus höger Light bulb, position light, right-hand
422 H G-lampa körvisare vä fram Light bulb, direction indicator left-hand
forward
423 H G-lampa körvisare hö fram Light bulb, direction indicator right-hand
forwrd
426 H G-lampa körvisare vä bak Light bulb, direction indicator left-hand rear
427 H G-lampa körvisare hö bak Light bulb, direction indicator right-hand rear
428 H G-lampa roterande varningsljus Light bulb, flashing beacon lamp

429 E G-lampa cigarettändare belysning Light bulb, cigarett lighter illumination
431 E G-lampa instrument belysning Light bulb, instrument illumination
432 E G-lampa handsfack belysning Light bulb, glove pocket light
433 E G-lampa instegs belysning Light bulb, step-in lighting
434 E G-lampa innerbelysning Light bulb, interior lighting
435 E G-lampa låsbelysning Light bulb, reading lighting
436 E G-lampa identifikationsljus Light bulb, identification light
437 E G-lampa identifikationsljus/takskylt Light bulb, identification light/roof sign
438 E G-lampa motorrumsbelysning Light bulb, engine compartment light
439 E Nummerskyltsbelysning Light license plate
440 E G-lampa värmereglage belysning Light bulb, heating control light
445 H G-lampa körvisare vä (extra) Light bulb, extra direction indicator left
446 H G-lampa körvisare hö (extra) Light bulb, extra direction indicator right
451 H G-lampa dimbakljus vänster Light bulb, fog light rear left
452 H G-lampa dimbakljus höger Light bulb, fog light rear right
453 H G-lampa bromsljus/körvisare vänster Light bulb, brake light/dir. indicator left-hand
453 H G-lampa bromsljus/körvisare höger Light bulb, brake light/dir. indicator right-hand
454 H G-lampa bromsljus blackout vänster Light bulb, brake light blackout left-hand
454 H G-lampa bromsljus blackout höger Light bulb, brake light blackout right-hand
456 E G-lampa backljus blackout IR vänster Light bulb, rear light blackout IR left-hand
456 E G-lampa backljus blackout IR höger Light bulb, rear light blackout IR right-hand
457 H G-lampa positionsljus blackout vänster Light bulb, position light blackout left-hand


457 H G-lampa positionsljus blackout höger Light bulb, position light blackout right-hand
458 E G-lampa fram blackout vänster Light bulb, roading light blackout left-hand
458 E G-lampa fram blackout höger Light bulb, roading light blackout right-hand
459 E G-lampa fram blackout IR vänster Light bulb, roading light blackout IR left-hand
459 E G-lampa fram blackout IR höger Light bulb, roading light blackout IR right-
hand
460 E G-lampa arb.belysning hytt blackout IR vä Light bulb, working light cab blackout IR left
460 E G-lampa arb.belysning hytt blackout IR hö Light bulb, working light cab blackout IR right
461 E G-lampa arb.bel. bom 20' blackout IR vä Light bulb, working light boom20' b.out IR left
461 E G-lampa arb.bel. bom 20' blackout IR hö Light bulb, working light boom20' b.out IR
right
462 E G-lampa arb.bel. bom 40' blackout IR vä Light bulb, working light boom40' b.out IR left
462 E G-lampa arb.bel. bom 40' blackout IR hö Light bulb, working light boom40' b.out IR
right
463 H G-lampa bak ljus vänster bak, blackout Light bulb, rear light left-hand rear, blackout
463 H G-lampa bak ljus höger bak, blackout Light bulb, rear light right-hand rear, blackout
464 E G-lampa cont belysning IR vänster Light bulb,Container light IR left-hand

464 E G-lampa cont belysning IR höger Light bulb,Container light IR right-hand
465 H G-lampa röd saxagregat ute Light-bulb, red extender exended
466 H G-lampa orange vertikalhålning på Light bulb, orange vertical hold on
467 H G-lampa grön klämtryck OK Light bulb, green clamp pressure OK
468 G-Lampa Röd Maxlast Light bulb,Red Overload
500 H Kont lampa körvisare Indicating lamp, direction indicator
501 H Kont lampa körvisare (extra) Indicating lamp, direction indicator extra
503 H Varn lampa oljetryck motor Warning lamp, oil pressure engine
504 H Kont lampa helljus Indicating lamp, main beam
505 H Varn lampa laddning Warning lamp, loading
506 H Varn lampa laddning (extra) Warning lamp, loading extra
507 H Varn lampa färdbroms Warning lamp, brake
508 H Varn lampa parkerings broms Warning lamp, parking brake
509 H Varn lampa nivå kylvatten Warning lamp, coolant level
510 H Kont lampa diff spärr Indicating lamp, diff. interlock
512 H Varn lampa temp momentförst Warning lamp, temperature converter
514 H Kont lampa överväxel Indicating lamp, overdrive clutch
519 H Kont lampa halvljus Indicating lamp, dipped lights
524 H Kont lampa luftfilter Indicating lamp, air filter
525 H Kont lampa UNIKAT Indicating lamp, UNIKAT
528 H Kont lampa förvärmning Indicating lamp, preheating
530 H Kont lampa framhjuls styrning Indicating lamp, forward wheel steering
531 H Kont lampa 4-hjuls styrning Indicating lamp, 4-wheel steering
532 H Kont lampa crab styrning Indicating lamp, crab steering
533 H Kont lampa hyd.pump Indicating lamp, emergency hyd. pump
547 H Varn lampa centralvarning Warning lamp, central warning
549 H Varn lampa oljetryck v-låda Warning lamp, oil pressure gear box
550 H Varn lampa hyttlåsning Warning lamp, cab lock


551 H Varn lampa temp v-låda Warning lamp, temperature gear box
552 H Varn lampa bromstryck Warning lamp, brake pressure
554 H Varn lampa temp spolkrets bromsar Warning lamp, temp. cooling system brakes
555 H Varn lampa temp kylvatten mot Warning lamp, temperature coolant engine
556 H Varn lampa låsning vändskiva Warning lamp, interlocking of turntable

560 H Varn lampa temp drivmotor el Warning lamp, temperature, drive motor
561 H Varn lampa temp pumpmotor el Warning lamp, temperature, pump motor
562 H Varn lampa öppen twistlock Warning lamp, unlocked twist lock
563 H Varn lampa låst twistlock Warning lamp, locked twist lock
564 H Varn lampa anliggning Warning lamp, alignement
565 H Varn lampa temp motor el Warning lamp ,temperature motor
569 H Kont lampa elvärme Indicating lamp, electric heater
569 H Kont lampa elvärme Indicating lamp, electric heater
570 H Varn lampa överkoppling säkerhetssystem Warning lamp, by-pass safety system
571 H Kont lampa bränslenivå Indicating lamp, fuel level

572 H Varningslampa lyfthöjd Warning lamp lifting height
573 H Kontroll lampa motor information Indicator lamp engine information
574 H Kontroll lampa stödben nere Indicator lamp support jacks down
575 H Kontroll lampa stödben ur arb.läge Indicator lamp support jacks out of working
pos
576 H Kontroll lampa anliggning främre ben Indicator lamp, alignment front legs
577 H Kontroll lampa anliggning bakre ben Indicator lamp, alignment rear legs
578 H Kontroll lampa klämläge främre ben Indicator lamp, clamp position front legs
579 H Kontroll lampa klämläge bakre ben Indicator lamp, clamp position rear legs
580 H Kontroll lampa främre ben uppe Indicator lamp, front legs upper position
581 H Kontroll lampa främre ben nere Indicator lamp, front legs lower position
582 H Varningslampa överlast Warning lamp overload
583 H Kontroll lampa anliggning ett ben Indicator lamp, alignment one leg
584 H Kontroll lampa anliggning alla ben Indicator lamp, alignment all legs
599 H Kont lampa option Indicating lamp, option
600 Y M-ventil avgasbroms Solenoid valve, exhaust brake
601 Y M-ventil diff spärr Solenoid valve, diff. interlock
602 Y M-ventil broms Solenoid valve, brake
603 Y M-ventil värme Solenoid valve, heater
604 Y M-ventil kraftuttag sida Solenoid valve, power take off, side
605 Y M-ventil kraftuttag bak Solenoid valve, power take off, rear
606 Y M-ventil 2/4 hjulsdrift Solenoid valve, 2/4WD
607 Y M-ventil hög/låg växel Solenoid valve, high/low gear
608 M Pumpaggregat hyttlyft Pump unit, cab hoist
609 M Ställmotor gaspådrag Regulating motor, throttle
610 Y M-ventil hydraulsystem allm Solenoid valve, hydraulics, general
611 Y M-ventil flödesbegränsning Solenoid valve, flow restriction
612 M Ställmotor recirkulation Regulating motor, re-circulation
613 Y M-ventil momentförstärkare Solenoid valve, torque amplifier
614 Y M-ventil rangespärr Solenoid valve, ranging interlock
615 Y M-ventil hjulvridning Solenoid valve, wheel turning
616 Y M-ventil kallstart Solenoid valve, cold start aid
617 Y M-ventil AT-regulator by-pass Solenoid valve, AT-regulator ¿by-pass¿
618 Y M-ventil vatten klimatanläggning Solenoid valve, water air conditioner
620 Y M-ventil vändskiva upp Solenoid valve, fifth wheel up
621 Y M-ventil vändskiva ner Solenoid valve, fifth wheel down


622 Y M-ventil vändskiva fram Solenoid valve, fifth wheel forward
623 Y M-ventil vändskiva bak Solenoid valve, fifth wheel rear
624 Y M-ventil skevning hö Solenoid valve, levelling right hand
625 Y M-ventil skevning vä Solenoid valve, levelling left hand
626 Y M-ventil AT-regulator Solenoid valve, AT-regulator
627 Y M-ventil vakuum Solenoid valve vacuum
628 Y M-ventil bränsleblandning Solenoid valve fuelmixture
630 Y M-ventil v-låda fram Solenoid valve, gear box, forward gear
631 Y M-ventil v-låda back Solenoid valve, gear box, rear gear
632 Y M-ventil v-låda spole 1 Solenoid valve, gear box, 1 gear
635 Y M-ventil klämtryck Solenoid valve, clamping pressure
636 Y M-ventil styrning Solenoid valve, steering
637 Y M-ventil flytläge skevning Solenoid valve, equalizing fifth wheel
638 Y M-ventil stopp insprut pump Solenoid valve, stop injection pump
639 Y M-ventil låsning orbitrol ls Solenoid valve, locking LS orbitrol
640 Y M-ventil gasol Solenoid valve, LPG
641 Y M-ventil förångare (LPG) Solenoid valve, evaporator (LPG)
642 Y M-ventil park broms Solenoid valve, parking brake
643 Y M-ventil låsning stol (VBFS) Solenoid valve, seat locking (VBFS)
644 Y M-ventil låsning vändskiva Solenoid valve, fifth wheel locking
645 Y Magnetkoppling komp AC Magnetic clutch, compressor AC
646 Y M-ventil stolsvändning Solenoid valve, seat rotation
647 Y M-ventil stolstilt Solenoid valve, seat tilt
648 Y M-ventil luftfjädring Solenoid valve, pneumatic springing
649 B Termostat klimatannläggning Thermostat, air condition
650 M Torkarmotor fram
651 M Vindrutespolarmotor Washer motor
652 M Strålkastarmotor Light motor
653 M Strålkastarspolarmotor Light washer motor
654 M Startmotor Starter motor
655 M Kylfläkt drivmotor (EC) Cooling fan, main motor (EC)
656 M Kylfläkt elskåp (EC) Cooling fan, electrical box (EC)
657 M Fläktmotor värme Heating fan
658 G Generator (extra) Alternator extra
659 G Generator utan laddregulator Alternator without loading regulator
660 G Generator med laddregulator Alternator with loading regulator
661 M Fönsterhissmotor Screenelevator motor
662 G Laddregulator Loading regulator
663 M Doseringspump klimatanläggning Dosage pump, air condition
664 M Cirk pump klimatanläggning Circulating pump, air condition
665 V Diod Diode
666 M Fläktmotor cirkulation Circulation fan
667 M Cirkulationspump värmesystem Circulation pump heating system
668 M Kylfläkt hydraulolja Cooling fan, hydraulic oil
669 E Värmare kupe/ motor diesel Heater compartment/engine diesel
670 M Kompressor Compressor
671 M Doseringspump diesel Dosage pump diesel
672 M Spjäll motor, ECC Draught valve motor, ECC
673 Y Vatten ventil motor, ECC Water valve motor, ECC


674 M Kylfläkt bromsolja Cooling fan, brake fluid
675 M Motor, Stolsvändning Motor, Seat rotation
676 Y Solenoid Broms stolsvändning Solenoid brake , seat rotation
685 A Reglerenhet termostat AC Control unit, termostat AC
690 B Fartreglage (EC) Speed control (EC)
693 M Pump centralsmörjning Pump, central lubrication
694 M Styrmotor Steering motor
695 M Drivmotor (EC) Drive motor (EC)
696 M Pumpaggregate nödstyrning Pump, emergency steering
697 B Elbroms Electric brake
698 M Pumpmotor (EC) Pump motor (EC)
699 Y M-ventil option Solenoid valve, option
700 P Hastighetsmätare Speedometer
701 P Mätare oljetemp v-låda Gear box oil temperature gauge
702 P Klocka Clock
703 P Varvtalsmätare Engine rev meter
704 P Tryckluftsmätare Air pressure gauge
705 P Mätare oljetryck v-låda Gear box oil pressure gauge
706 P Termometer temp kylvätska motor Temperature gauge, engine coolant
707 P Bränslemätare Fuel gauge
708 P Timräknare Hour meter
709 P Kapacitetsmätare batteri Capacity gauge, battery
710 P Tidur motor/kupevärmare Timer, engine- and cab heater
711 P Räknare, impuls Counter, impulse
712 P Mätare oljetryck motor Motor oil pressure gauge
714 P Mätare, temp. Hydraulolja Hydraulic fluidtemperature, guage
715 P Extra instrument allm Extra instrument, general
720 S Givare vändbar förarstol Transmitter, revolving driver´s seat (VBFS)
740 D FleetManager kontrollenhet FleetManager control unit
741 U FleetManager batterifilter FleetManager battery filter
742 D FleetManager kortläsare FleetManager card device
743 D FleetManager accelerations givare FleetManager acceleration sensor
751 B Givare varvtal turbin Transmitter, speed turbin
752 B Givare varvtal inre växellåda Transmitter, speed internal gear chain
753 B Varvtalsgivare motor Transmitter, engine revolution
754 B Givare lufttryck Transmitter, air pressure
755 B Givare hydraulfilter indikering Transmitter, hydraulics filter indication
756 B Temperatur kylvätska motor Transmitter, engine coolant temperature
757 B Bränslenivågivare Transmitter, fuel level
758 B Varvtalsgivare v-låda Transmitter, gear box revolution
759 B Nivåindikator kylvätska Transmitter, coolant level
760 B Givare rev-spärr/aut-vxl trans Transmitter, reversing interlock / automatic
gear change system (on gearbox output
shaft)
761 B Givare rev-spärr/aut-vxl motor Transmitter, reversing interlock / automatic
gear changing system (engine speed)
762 B Givare temp,spolkrets bromsar Transmitter, brake flushing circuit

763 B Givare nivå hydraulolja Transmitter, hydraulic fluid level
764 B Givare servotryck växellåda Transmitter, gear box servo pressure
765 B Givare oljetryck v-låda Transmitter, oil pressure gear box
766 B Givare oljetemp. v-låda Transmitter, oil temperature gear box
767 B Givare oljetryck motor Transmitter, oil pressure engine
768 B Givare oljetryck hydraulik Transmitter, hydraulic pressure


769 B Givare ändläge Transmitter, end position
770 B Givare rattutslag Transmitter, steering wheel angle
771 B Givare vinkel Transmitter, angle
772 B Givare temp bromsolja Transmitter, temperature brake fluid
773 B Givare närvaro Transmitter, presence
774 B Givare utomhustemp Transmitter, ambient temperature
775 B Givare temp klimatanläggning Transmitter, temperature air condition
776 B Givare temp hydraulolja Transmitter, hydraulic temperature
777 B Givare läge Transmitter, position
778 B Givare drivbrytning Transmitter, drive break
779 A Reglersystem återladdning (EC) Control system, recharging (EC)
780 A Reglersystem åkmotor (EC) Control system main motor (EC)
781 A Reglersystem pumpmotor (EC) Control system pump motor (EC)
782 A Logik interface 2 drivmotorer Logic (interface) two main motors (EC)
783 A Logik interface gaspådrag Logic (interface) throttle
784 A Logik interface bromsregl Logic (interface) brake control
785 A Logik interface styrsystem Logic (interface) control system
786 A Servoförstärkare styrsystem Servo amplifier steering system
789 B Givare allmän Transmitter, common
790 D Elektronisk kontrollenhet ECU, hytt Electronic Control Unit ECU, cab
791 D Elektronisk kontrollenhet aggregat Electronic Control Unit, attachment
792 D Elektronisk kontrollenhet styrning Electronic Control Unit, steering system
793 D Elektronisk kontrollenhet växellåda Electronic Control Unit, gearbox
794 D Elektronisk kontrollenhet motor Electronic Control Unit, engine
795 P Display Display
796 D Elektronisk kontrollenhet, lasthantering Electronic Control Unit, Loadhandling
797 D Elektronisk kontrollenhet, ram Electronic Control Unit, frame
798 D Elektronisk kontrollenhet, stolvändning Electronic Control Unit, seat rotation
799 A Logik allm (option) Logic, general (option)
800 S Startelement Start element
802 E Eluppvärmd backspegel Electrical heated observation mirror
803 E Eluppvärmd stol Electrical heated seat
804 E Cigarettändare Cigarett lighter
805 E Elvärme hytt Electrical heating cab
806 A Aggregat klimatanläggning Aggregate, air conditioner
807 R Potentiometer Potentiometer
808 E Eluppvärmd lufttorkare Electrical heater air dryer
810 A Kondensor AC, fläkt Condensor AC, fan
815 S Manöverspak Control lever
820 R Motstånd Resistor
821 C KONDENSATOR CAPACITOR
822 Z Signalfilter Signal filter
823 U Signalomvandlare höger Signal amplifier, right
824 U Signalomvandlare vänster Signal amplifier, left
825 R Reglage spakstyrning Controls, (steering with control levers).
826 Y Ventil spakstyrning Valve, (steering with control levers).
827 A Växellåda Gearbox
828 R Shuntmotstånd Shunt-resitor
830 L Tändspole Ignition coil
835 E Tändstift Ignition plug
840 S Strömfördelare Distributor
850 H Signalhorn Horn
853 H Summer Buzzer
888 E Lufttork, kompressor Air Dryer, Compressor


900 A Radio/bandspelare Radio/tape recorder
901 U Spänningsomvandlare Voltage converter
902 B Högtalare Loud speaker
903 W Antenn radio Aerial, radio
905 A Kommunikationsradio Communication radio
906 W Antenn kommunikationsradio Aerial, communication radio
907 A Monitor Monitor
908 A Kamera Camera
909 A Skrivare Printer
910 U Spänningsomvandlare 80V/24V Voltage converter 80 V / 24 V
911 A Dataterminal Dataterminal
940 A Logik batterivakt Logic switch , battery watch
941 U Laddningsutjämnare Even charger
950 A Logik transistortändning Logic transistor ignition
955 A Logik övervarvningsskydd (LPG) Logic overspeed protection (LPG)
960 A Logik rev-spärr/aut-vxl Logic unit, reversing interlock/automatic gear
changing
961 A Motor/kupevärmare Engine- and cab heater
962 E Logik slitageind kol elmotor Logic indication of wear, brush electrical
motor
965 H Backvarnare Reversing alarm
1001 S Strömställare, TW Switch, TW
1002 S Strömställare, lossa TW Switch, unlocking of TW
1003 S Strömställare, låsa TW Switch, locking of TW
1004 S Strömställare, stopp vid 30'-35' Switch, stop at 30 -35¿
1005 S Strömställare, förbikoppling av Switch, overriding of the safety system
säkerhetssystem
1006 S Strömställare, fällning främre ben Switch, front legs down
1007 S Strömställare, fällning bakre ben Switch, rear legs down
1008 S Strömställare, klämma/lossa ben Switch, clamping/-releasing legs
1009 S Strömställare, Motor information Switch, Engine information
1010 S Srömställare, tilt av hytt Switch, tilt of cab
1011 S Strömställare IR ljus Switch IR light
1012 S Strömställare utskjut 20¿-40¿ Switch, Extension 20¿-40¿
1013 S Strömställare stödben Switch, Support jacks
1014 S Strömställare förbikoppling rotationstopp Switch, over ride rotation stop
1015 S Strömställare förbikoppling höjdbeg/tp-beg Switch, over ride height limit/tp-limit
1016
1017 S Strömställare diagnostik öka/minska Switch, diagnostics increase/decrease
1018 S Strömställare diagnostik on/off Switch, diagnostics on/off
1019 S Strömställare rastvärme Switch, paus heat
1020 S Strömställare automatisk släpp/kläm Switch automatic release/clamp funktion
funktion
1021 S Strömställare sax Switch extender
1022 S Strömställare vertikalhållning Switch, vertical position
1023 S Strömställare låsning övre arm Switch, lock upper arm
1024 S Strömställare Korta Armen av/på Switch, Short Arm on/off
1025 S Strömställare pappersfunktioner av/på Switch, paper funktions on/off
1026 S Strömställare omkoppling Switch, switch papper/bale clamp
pappers/klämmagregat
1027 S Strömställare lyfthöjdsförval Switch, lift height selection
1028 S Strömställare lyfthöjdsförval öka Switch, lift height selection increase
1029 S Strömställare lyfthöjdsförval minska Switch, lift height selection decrease


1030 S Strömställare läraringång givare ultraljud Switch, teaching ultrasonic sensor
1031 S Strömställare, Over Height Upp/Ned Switch, Over Height Up/Down
1032 S Brytare backljus Switch reverse light.
1033 S Flytta korta armen Move short arm
1034 S Strömställare förbikoppling startspärr Switch Override Start interlock
1035 S Strömställare Val av klämtryck Switch, Clamp pressure selection
1036 S Strömställare Korta Armen av/på Switch , Short Arm on/off
1037 S Strömställare låsning skevning Switch, lock levelling
1038 S Strömställare Övre armpar/Sidoföring Switch Upper arms/Sideshift
1039 S Strömställare Inching Switch, Inching
1040 S Switch stopp motor Switch, Stop engine
1041 S Strömställare motorrumsbelysning Switch, light engine compartment
1042 S Strömställare höjdjustering stol Switch, Seat height level
1043 S Strömställare längdjustering stol Switch, Seat for/aft adjustment
1044 S Strömställare Tankväljare Switch, Tankselector
1045 S Strömställare Avstängning backalarm Switch, Rev. Alarm on/off
2000 D Elektronisk kontrollenhet, proportionalventil Electronic control unit, propotional valve
3001 K Relä rotation Relay, rotation

3002 K Relä tilt Relay, tilt
3003 K Relä sidoföring Relay, side shifting
3004 K Relä längdinställning Relay, length adjustment
3005 K Relä twist lock Relay, twist lock
3006 K Relä spridning Relay, spreading
3007 K Relä lyft/sänk Relay, lifting/lowering
3008 K Relä hydraulfunktion extra Relay, extra hydraulic function
3009 K Relä manöverbrytare hydr Relay, operating switch
3010 K Relä bromsljus vxl std/blackout Relay, brake light shift std/blackout
3011 K Relä backljus vxl std/blackout Relay, reversing light shift std/blackout
3012 K Relä arb.bel hytt vxl std/blackout Relay, working light cab, shift std/blackout
3013 K Relä arb.bel. bom 20' vxl std/blackout Relay,working light boom20' shift std/b.out
3014 K Relä arb.bel. bom 40' vxl std/blackout Relay,working light boom40' shift std/b.out
3015 K Relä vxl bromsljus/blinkers vä Relay, shift brake light/direction indicator left
3015 K Relä vxl bromsljus/blinkers hö Relay, shift brake light/direction indicator

right
3016 K Relä signalhorn relay, horn
3017 K Relä containerbelysning Relay, Container light
3018 K Relä containerbelysning IR Relay, Container light IR
3305 K Relä VBFS, backljus Relay, rotating driver´s seat, reversing light
3306 K Relä VBFS, helljus Relay, rotating driver´s seat, main beam
3307 K Relä VBFS, halvljus Relay, rotating driver´s seat, dipped beam
3308 K Relä VBFS, bromsljus Relay, rotating driver´s seat, brake light
3310 K Relä VBFS, körvisare vä Relay, rotating driver´s seat, direction
indicator left
3311 K Relä VBFS, körvisare hö Relay, rotating driver´s seat, direction
indicator right
3330 K Relä, säkerhetsbälte Relay, seat belt
3331 K Relä VBFS, drivning fram Relay, rotating driver´s seat, forward driving


3332 K Relä VBFS, drivning bak Relay, rotating driver´s seat, reversing
driving
3349 K Relä VBFS, fartreglage Relay, rotating driver´s seat, speed control
3404 K Relä VBFS, mastljus Relay, rotating driver´s seat, mast light
3412 K Relä bak ljus Relay, rotating driver´s seat, rear light
3768 K Relä oljetryck hydraulik Relay, hydraulic pressure
3769 K Relä, blockering av hyttilt Relay, blocking of cab tilt
3770 K Relä anliggning Relay, alignment
3771 K Relä Krok Relay, Hook
3772 K Relä laddsignal (D+) Relay, charge signal (D+)
3773 K Relä 12V för minne radio Relay 12V for radio memory
3774 Relä kylfläkt olja Relay, cooling fan oil
3775
5000 H Kont lampa tryck lyfttång Indicating lamp, pressure lift tong
5001 H Varn lampa, Over Height ben uppe Warn. Lamp, Over Height leg upper pos
6001 Y M-ventil blockering höger Solenoid valve, blocking right
6002 Y M-ventil blockering vänster Solenoid valve, blocking left
6003 Y M-ventil inkoppling av hydraulik till topplyft Solenoid valve, activation of toplift hydraulics
6004 Y M-ventil sänk Solenoid valve, lower

6005 Y M-ventil lyft Solenoid valve, lift
6006 Y M-ventil bom ut Solenoid valve, boom out
6007 Y M-ventil bom in Solenoid valve, boom in
6008 Y M-ventil vridning medsols Solenoid valve, rotation clockwise
6009 Y M-ventil vridning motsols Solenoid valve, rotation counter-clockwise
6010 Y M-ventil tilt ut Solenoid valve, tilt out
6011 Y M-ventil tilt in Solenoid valve, tilt in
6012 Y M-ventil tilt Solenoid valve, tilt
6013 Y M-ventil fällning främre ben Solenoid valve, lowering front legs
6014 Y M-ventil fällning bakre ben Solenoid valve, lowering rear legs
6015 Y M-ventil klämma/lossa ben Solenoid valve, clamping/releasing legs
6016 Y M-ventil Hyttskjutning fram Solenoid valve, cab movement forward
6017 Y M-ventil Hyttskjutning bak Solenoid valve, cab movement reverse
6018 Y M-ventil spridning ut Solenoid valve, spreading out
6019 Y M-ventil spridning in Solenoid valve, spreading in
6020 Y M-ventil sidoföring vänster Solenoid valve, side shift left
6021 Y M-ventil sidoföring höger Solenoid valve, side shift right
6022 Y M-ventil extra hydraulfunktion ut Solenoid valve, extra hydraulic function out
6023 Y M-ventil extra hydraulfunktion in Solenoid valve, extra hydraulic function in

6024 Y M-ventil stativ ut Solenoid valve, mast out
6025 Y M-ventil stativ in Solenoid valve, mast in
6026 Y M-ventil höger framhjul styrning vänster Solenoid valve, right front wheel, steering left
6027 Y M-ventil höger framhjul styrning höger Solenoid valve, right front wheel, steering
right
6028 Y M-ventil vänster framhjul styrning vänster Solenoid valve, left front wheel, steering left
6029 Y M-ventil vänster framhjul styrning höger Solenoid valve, left front wheel, steering right
6030 Y M-ventil höger bakhjul styrning vänster Solenoid valve, right rear wheel, steering left


6031 Y M-ventil höger bakhjul styrning höger Solenoid valve, right rear wheel, steering
right
6032 Y M-ventil vänster bakhjul styrning vänster Solenoid valve, left rear wheel, steering left
6033 Y M-ventil vänster bakhjul styrning höger Solenoid valve, left rear wheel, steering right
6034 Y M-ventil skevning Solenoid valve, levelling

6035 Y M-ventil skevning höger Solenoid valve, levelling right
6036 Y M-ventil skevning vänster Solenoid valve, levelling left
6037 Y M-ventil kylfläkt Solenoid valve, Cooling fan
6038 Y M-ventil frikoppling koppling Solenoid valve, lockup clutch
6039 Y M-ventil öppna twistlock Solenoid valve, unlocked twist lock
6040 Y M-ventil låsa twistlock Solenoid valve, locked twist lock
6041 Y M-ventil nöd, twistlock Solenoid valve, emergency, twistlock
6042 Y M-ventil mellan bom Solenoid valve, middle boom
6043 Y Magnetventil, fällning torn (RTCH) Solenoid valve, boom lowering (RTCH)
6044 Y M-ventil blockering twistlock Solenoid valve, blocking twistlock
6045 Y M-ventil blockering lyft Solenoid valve, blocking lift
6046 Y M-ventil utskjut Solenoid valve, projecting
6047 Y M-ventil, hyttilt upp Solenoid valve, cab tilt up
6048 Y M-ventil, hyttilt ner Solenoid valve, cab tilt down
6049 Y M-ventil, kylkrets broms Solenoid valve, cooling cicuit brake
6050 Y M-ventil blockering utskjut Solenoid valve, blocking projecting
6051 Y M-ventil, regenerering höger Solenoid valve, regeneration right
6052 Y M-ventil, regenerering vänster Solenoid valve, regeneration left
6053 Y M-ventil, körläge Solenoid valve, driving position
6054 Y M-ventil, klämma ihop Solenoid valve, clambing in
6055 Y M-ventil, klämma isär Solenoid valve, clambing out
6056 Y M-ventil, främre knä ut Solenoid valve, front knee out
6057 Y M-ventil, främre knä in Solenoid valve, front knee in
6058 Y M-ventil, bakre knä ut Solenoid valve, rear knee out
6059 Y M-ventil, bakre knä in Solenoid valve, rear knee in
6060 Y M-ventil, främre ben upp Solenoid valve, front legs up
6061 Y M-ventil, bakre ben upp Solenoid valve, rear legs up
6062 Y M-ventil, urkoppling hydraulpump Solenoid valve interruption hydraulic pump
6063 Y M-ventil, stödben upp Solenoid valve, brace up
6064 Y M-ventil, stödben ner Solenoid valve, brace down
6065 Y M-ventil, frikoppling vridbroms Solenoid valve, lockup rotation brake
6066 Y M-ventil, v-låda, drivning Solenoid valve, gearbox, drive
6067 Y M-ventil, v-låda, oljetryck till 1:a/3:e växeln Solenoid valve, gearbox,oilpressure to
1st/3rd gear
6068 Y M-ventil sax/rotation Solenoid valve externder/rotation
6069 Y M-ventil, v-låda, oljetryck till 2:a/4:e växeln Solenoid valve, gearbox,oilpressure to
2nd/4th gear
6070 Y M-ventil Over Height upp Solenoid valve, Over Height up
6071 Y M-ventil Over Height ner Solenoid valve, Over Height down
6072 Y M-ventil klämtryck Solenoid valve clamp pressure
6073 Y Propertional ventil, Opti speed Proportional valve, Opti speed
6074 Y M-ventil, v-låda, växelväljare för 2:a/4:e Solenoid valve, gearbox, gearswitch for
växeln 2nd/4th gear
6075 Y M-ventil, v-låda, växelväljare för 1:a/3:e Solenoid valve, gearbox, gearswitch for
växeln 1st/3rd gear
6076 Y M-ventil blockering sänk Solenoid valve, blocking lower
6077 Y M-ventil Inching Solenoid valve, Inching


6078 Y M-ventil,Avstängning Övre klämarm Solenoid valve, upper arm off
6079 Y M-Ventil, Sidoföring/Övre armar Solenoid valve, Sideshift/Upper arms
6080 Y M-ventil, aktivering hyttkörning Solenoid valve, activate sliding cab
7200 S Givare, axeltryck höger Sensor, axle pressure right
7201 S Givare, axeltryck vänster Sensor, axle pressure left
7202 S Givare, anliggning vänster fram Sensor, alignment left front
7202 S Givare, anliggning höger fram Sensor, alignment right front
7203 S Givare, anliggning vänster bak Sensor, alignment left rear
7203 S Givare, anliggning höger bak Sensor, alignment right rear
7204 S Givare, öppen vänster twistlock Sensor, unlocked twistlock left
7204 S Givare, öppen höger twistlock Sensor, unlocked twistlock right
7205 S Givare, låst vänster twistlock Sensor, locked twistlock left
7205 S Givare, låst höger twistlock Sensor, locked twistlock right
7206 S Givare, gaffel aggregat Sensor, fork attachment
7207 S Givare, 2WD/4WD Sensor, 2WD/4WD
7208 S Givare, hytt i körläge Sensor, Cab in drive position
7209 S Givare, oljefilter indikering Sensor, Oil filter indication
7210 S Givare, hytt i transportläge Sensor, Cab in transportation position
7211 S Givare, lyfthöjd Sensor, lifting height
7212 S Givare, körläge Sensor, driving position
7213 S Givare, Anliggning främre ben Sensor, Alignment front legs
7214 S Givare, Anliggning bakre ben Sensor, Alignment rear legs
7215 S Givare, kläm främre ben Sensor, Clamp front legs
7216 S Givare, kläm bakre ben Sensor, Clamp rear legs
7217 S Givare, främnre knä Sensor, front knee
7218 S Givare, bakre knä Sensor, rear knee
7219 S Givare, främre ben Sensor, front legs
7220 S Givare, bakre ben Sensor, rear legs
7221 S Givare, styraxel Sensor, steering axle
7222 S Givare, stödben uppe Sensor, brace up
7223 S Givare, stödben nere Sensor, brace down
7224 B Givare, mätläge våg Sensor, measurepoint scale
7225 B Givare, rotationsstopp Sensor, rotation stop
7226 B Givare, tryck lyftcylinder Sensor, pressure lift cylinder
7227 B Givare, tryck klämma Sensor, pressure clamp
7228 B Givare lyfthöjd analog Sensor lift height analogue
7229 B Givare tiltvinkel analog Sensor tilt angle analogue
7230 B Givare ultraljud last position Sensor, ultrasonic load position
7231 B Givare, Over Height, Ben uppe Sensor, Over Height, Leg upper position
7232 B Givare,IR Last position Givare,IR Load position
7233 B Givare lambda sond Sensor lambda sond
7234 B Givare vatten i bränsle Transmitter water in fuel
8071 R Potentiometer lyft/sänk Potentiometer lift/lower
8072 R Potentiometer tilt Potentiometer tilt
8073 R Potentiometer sidoföring Potentiometer side shifting
8074 R Potentiometer spridning Potentiometer spreading
8075 R Potentiometer extra Potentiometer extra
8076 R Potentiometer mast in/ut Potentiometer reach in/out
8077 R Potentiometer höger framhjul Potentiometer right front wheel
8078 R Potentiometer vänster framhjul Potentiometer left front wheel
8079 R Potentiometer höger bakhjul Potentiometer right rear wheel
8080 R Potentiometer vänster bakhjul Potentiometer left rear wheel
8081 R Potentiometer tiltvinkel Potentiometer tilt angle
8082 R Potentiometer fläkthastighet, ECC Potentiometer fan speed, ECC


8083 R Potentiometer temperatur, ECC Potentiometer temperature, ECC
8084 R Potentiometer spjäll, ECC Potentiometer draught valve, ECC
8085 R Potentiometer rotation Potentiometer rotation
8086 R Potentiometer sax Potentiometer extender
8087 R Potentiometer klämma Potentiometer clamp
8088 R Potentiometer skevning Potentiometer levelling
8089 R Potentiometer kroklåsning Potentiometer flaps
8090 V Laser, pappersaggretgat Lase, Pulp an Paper
8091
9000 M Motor höj/sänkbar stolspelare Motor rise/lower seat column
9001 D Åkerströms fjärrkontroll Åkerströms Remote Control
9002
9003 H Varningssignal aut. rörelse Warning alarm aut. movement
9888 A test
93774 K Relä hållkrets Relay, Holdcircuit

F Technical data 1
F Technical data
Table of Contents F Technical data

mm mm mm mm mm mm
Technical data ................................................................................................ 3

Specifications for data and volume ........................................................................ 3
Specification for lifting capacity and dimensions .................................................... 6
Oils and lubricants, recommendation ..................................................................... 9
Tightening torques, recommendations ................................................................. 11
Tightening torques, ORFS-couplings ................................................................... 12
Tightening torque, climate control system connections ........................................ 14
Unit explanations .................................................................................................. 14
Conversion table, SI-units .................................................................................... 15
Conversion table, length ....................................................................................... 16
Conversion table, area ......................................................................................... 16
Conversion table, volume ..................................................................................... 16
Conversion table, weight ...................................................................................... 17
Conversion table, pressure .................................................................................. 17

2 F Technical data

F Technical data – Technical data 3
Technical data
mm mm mm mm mm mm
Specifications for data and volume

page
–
Data
DCF 280-330 DCF 330 DCF 370-500
1 Engine Cummins Volvo Volvo Cummins Volvo Volvo

QSB6.7 TAD760VE TAD950VE QSM11 TAD952VE TAD1250VE
Power acc. to ISO 3046 (net power) 194 kW at 181 kW at 210 kW at 261 kW at 252 kW at 247 kW at
2200 rpm 2300 rpm 1800 rpm 2000 rpm 1900 rpm 1900 rpm
186 kW at
2000 rpm
Torque ISO 3046 990 Nm at 1100 Nm at 1275 Nm 1830 Nm 1735 Nm at 1760 kW at

1500 rpm 1500 rpm at 1000- at 1100- 1300 rpm 1400 rpm
1500 rpm 1400 rpm
Alternator, output 1680 W 1920 W 2400 W 1920 W
Start battery, voltage – capacity 2x12 V – 140 Ah
2 Transmission Dana-Spicer Off Highway TE17312 Dana-Spicer Off Highway TE32418
No. of gears forward – reverse 3-3 4-4
DCF 280-330 DCF 370-500
3 Driveline/axle AxleTech
Drive axle, type PRC3806W4H PRC7534W4H
4 Brakes
Parking brake Spring brake - Drive wheels
Service brake Wet Disc Brakes - Drive wheels
5 Steering Hydraulic servo
6 Suspension DCF 280-330 DCF 370-420 DCF 450-500
Dimension, front and rear 16.00x25 18.00x25 18.00x33
Tyre pressure (also see pressure 1.0 MPa

plate)

4 F Technical data – Technical data
9.6 Frame, body, cab and accessories, lighting system

DCF 280-500
Bulb
Control lights 1.2 W2x4.6d
Interior lighting 10 S8.5
Tail light 5 BA15s
Brake light 21 BA15s
Driving direction indicator 21 BA15s
Running lights 5 W2.1x9.5d
Headlights (high and low beams) 55/50 P43t-38
Reversing light 70 PK22s
Working lights 70 PK22s
35 D1S Xenon tubes. The insert and ballast

Working light Xenon must be changed as a unit.
Rotating beacon 70 PK22s
Volumes
For oil types see Oils and lubricants, recommendation page 9.
DCF 280-330 DCF 330 DCF 370-500
1 Engine Cummins Volvo Volvo Cummins Volvo Volvo

QSB6.7 TAD760VE TAD950VE QSM11 TAD952VE TAD1250VE
Engine oil incl. filter 20 litres 23 litres 35 litres 34 litres 35 litres 35 litres
Fuel tank 400 litres
Fuel quality Diesel according to EN590.
Cooling system 40 litres 27 litres 52 litres 40 litres 52 litres 40 litres
2 Transmission Dana-Spicer Off Highway TE17312 Dana-Spicer Off Highway TE32418
Total oil volume, gearbox 37 litres 80 litres
Gearbox oil volume during change 27 litres 60 litres

3. Driveline/axle AxleTech PRC3806W4H AxleTech PRC7534W4H
Differential 33 litres 50 litres
Hub reduction 2x10.5 litres 2x10 litres
4 Brakes
– Tank volume, 170 litres
Brake fluid system, volume
7 Load handling
Oil volume, planetary gear, hydraulic 1,6 litres
motor
Oil volume, hydraulic motor, disc brake 0,6 litres

DCF 280-330 DCF 370-500
Refrigerant, air conditioning R134a
Refrigerant volume See air conditioning plate
Lubricant, air conditioning ZEXEL PAG oil ZXL100 (1.7 DL)
Windshield washer fluid, volume 5 litres
Hydraulic oil tank 600 litres

Specification for lifting capacity and

page
–
dimensions
H5
H4
H3
H6
H8 H2
a
S L3 L2 L4
L L1
55
A1
DCF500-12
50 100 100
DCF450-12
45
DCF420-12
40
b
DCF370-12 V1 V B
35
DCF330-12
DCF300-12
30
DCF280-12
25
R2
20 R1
010586
15
600 900 1200 1400 1600 1800 2000
Specified measurements explained in table below.
Capacity and DCF280-12 DCF300-12 DCF330-12 DCF370- DCF420- DCF450- DCF500-

dimensions 12 12 12 12
• LB • LB • LB
Lifting capacity
Classed (kg) 28000 30000 33000 37000 42000 45000 50000
Centre of gravity distance

1200
(L4 [mm])
Dimensions, truck
Truck length without forks
6675 6925 7345 7845 7950 8550
(L [mm])
Truck width (W [mm]) 3410 4150


Height, basic machine

3650 3415 3650 3415 3650 3415 3725 3825
(H6 [mm])
Seat height (H8 [mm]) 2300 2350 2450
Distance between centre

of front axle and front of 1125 1295 1400 1440
fork arm (L2 [mm])
Axle distance (L3 [mm]) 4500 4750 5000 5500 6000
Track (c-c), front - rear (S

2540 - 2440 3030 - 2625 3030 - 2815
[mm])
Slewing radius, outer (R1

6600 6900 7400 8150 8650
[mm])
Slewing radius, inner (R2

950 1000 1100 1200
[mm])
Ground clearance, min. 300

[mm]
Max. height during cab

- 3800 - 3800 - 3800 -
tipping, (T1 [mm])
Max. width during cab tip-

- 3850 - 3850 - 3850 -
ping, (T2 [mm])
Min. running width at 90 °

stacking with forks (A1 10325 10795 11295 12100 12600
[mm])
Dimensions, Standard duplex mast

Lifting height (H4 [mm]) 5000
Mast height, min. (H3 4520 5050

[mm])
Mast height, max. (H5

6770 7550
[mm])
Mast tilt, forward - rear-

5 - 10
ward (α - β [°])
Ground clearance, min.

-
under mast (mm)
Dimensions, forks
Width (b [mm]) 300
Thickness (a [mm]) 110 135 145
Fork arm length (l [mm]) 2400


Width straight across fork

arms, max. - min. (V 2750 - 1550 2750 - 1950
[mm])
Side shift ±at width

200 -
straight across fork arms 300 - 2150 200 - 2350
2300
(V1 - V [mm])
Weight
Service weight [kg] 40600 49300 51900 54800 61000
Axle pressure front, (with-

19600 25500 27400 27600 33000
out load) [kg]
Axle pressure front, (with

69300 69100 68800 81000 88600 93900 105000
classed load) [kg]
Axle pressure rear, (with-

21000 23800 24500 27200 28000
out load) [kg]
Axle pressure rear, (with

4300 4500 4800 5300 5500 5900 6000
classed load) [kg]

Oils and lubricants,

page
–
recommendation
The service intervals indicated by Kalmar Industries in the mainte-
nance manual only apply if oils are selected according to the table be-
low. The table indicates recommended viscosity for different oil types
and qualities depending on the ambient temperature.
Any deviation from this table must be approved in writing by Kalmar
Industries, and may mean changed service intervals.
Oil type, quality °C -40 -30 -20 -10 0 +10 +20 +30 +40
°F -40 -22 -4 +14 +32 +50 +68 +86 +104
1.8 Engine, lubrication*)
Volvo TAD760VE: VDS-3**) SAE 15W40 (engine oil)

Volvo TAD950VE and TAD952VE: SAE 5W30 (engine oil)
VDS-3***)
Volvo TAD1250VE: VDS-3****)
Cummins: API CH-4 or ACEA E5
2.6 Transmission, lubrication sys-

tem
ATF DEXRON III DEXRON III
3.3 Driveline/axle, drive axle
API GL-5 SAE 80W140
SAE 75W90
4.8 Brake system (UTTO oil) *****)
GM Allison C-4 SAE 5W30 (transmission oil)

John Deere J20 C, D
Caterpillar TO-4
7 Load handling
Planetary gear, hydraulic motor, SAE 80W140

hypoid oil API GL-5
SAE 75W90
Disc brake, hydraulic engine, see "10
Common hydraulics" below.
DIN 51524 Part 3 HVLP ISO VG 68
ISO VG 46 HV
ISO VG 32

NOTE
The change interval for engine oils is conditional on the sulphur
content in the fuel does not exceed 0.5 %.
Oil filters shall always be changed in connection with oil change.
*) NOTE! API: CH-4 or CI-4 is approved for markets outside of Europe
(instead of ACEA E5).
**) Engine oil that fulfills both VDS-2 and ACEA E5 may be used.
***) Engine oil that fulfills both VDS-2 and ACEA E5 may be used pro-
vided that the oil change interval is reduced to 250 hours.
****) Engine oil that fulfills both VDS-2 and ACEA E5 may be used pro-
vided that the oil change interval is reduced to 400 hours.
*****) The fluid in the brake system must be UTTO (Universal Tractor
Transmission Oil).
VDS = Volvo Drain System.
ACEA = Association des Constructeurs Européenne d’Automobiles.
API = American Petroleum Institute.
Grease
Use a universal grease type EP according to NLGI Grade 2 with 3-5%
molybdenum sulphide content for all grease points except glide plates
where lubrication paste Gleitmo 805 or the equivalent shall be used.
For connectors, use contact grease 923836.0552.
Sealant silicone
Use Loctite 5972 or Loctite 598 (or equivalent). If uncertain, contact
Kalmar Industries.

Tightening torques,
page
–
recommendations
The tightening torques in the following table are recommendations
when tightening bolts and nuts.
When torquing using a machine, for example, bolt runner, the tighten-
ing torque should be reduced by approx. 5%.
For mild surfaces (hardness below 200 HB), washer shall be used un-
der both bolt head and nut. Alternatively, use flange bolt or flange nut.
Tighten to the prescribed torque without stopping.
Recommended tightening torque may vary depending on surface
treatment. Certain combinations of nut and bolt require lubrication ac-
cording to the table below.
State Screw Nut Lubrication
1 untreated untreated oil
2 bright-galvanized untreated or bright-galvanized dry or oil
3 hot-galvanized untreated dry or oil
Quality 8,8 10,9 12,9
State 1 2 3 1 1
Fine M-thread
M81 27 Nm 24 Nm 30 Nm 39 Nm 46 Nm
M101,25 54 Nm 48 Nm 61 Nm 78 Nm 91 Nm
M121,25 96 Nm 85 Nm 108 Nm 135 Nm 162 Nm
M161,5 230 Nm 205 Nm 260 Nm 323 Nm 388 Nm
M181,5 330 Nm 294 Nm 373 Nm 466 Nm 559 Nm
M-thread
M4 3.2 Nm 2.9 Nm 3.6 Nm 4.6 Nm 5.5 Nm
M5 6.4 Nm 5.7 Nm 7.2 Nm 9.1 Nm 11 Nm
M6 11 Nm 9.8 Nm 12.5 Nm 16 Nm 19 Nm
M8 26 Nm 24 Nm 30 Nm 38 Nm 45 Nm
M10 52 Nm 47 Nm 59 Nm 74 Nm 89 Nm
M12 91 Nm 81 Nm 103 Nm 128 Nm 154 Nm
M16 220 Nm 198 Nm 250 Nm 313 Nm 375 Nm
M20 430 Nm 386 Nm 490 Nm 620 Nm 732 Nm
M24 750 Nm 668 Nm 848 Nm 1050 Nm 1270 Nm
M30 1480 Nm 1317 Nm 1672 Nm 2080 Nm 2500 Nm
UNC-thread

Quality 8,8 10,9 12,9
1/4 12.5 Nm 11.1 Nm 14.1 Nm 17.6 Nm 20 Nm
5/16 25 Nm 22.3 Nm 28.3 Nm 35 Nm 42 Nm
3/8 44 Nm 39 Nm 50 Nm 62 Nm 73 Nm
7/16 70 Nm 62 Nm 79 Nm 100 Nm 118 Nm
1/2 107 Nm 95 Nm 121 Nm 151 Nm 178 Nm
9/16 153 Nm 136 Nm 173 Nm 216 Nm 255 Nm
5/8 210 Nm 187 Nm 237 Nm 298 Nm 353 Nm
3/4 370 Nm 390 Nm 418 Nm 524 Nm 619 Nm
7/8 594 Nm 528 Nm 671 Nm 839 Nm 990 Nm
1 889 Nm 791 Nm 1005 Nm 1260 Nm 1480 Nm
1 1/8 1260 Nm 1120 Nm 1424 Nm 1780 Nm 2100 Nm
1 1/4 1760 Nm 1565 Nm 1990 Nm 2490 Nm 2940 Nm
1 3/8 2320 Nm 2065 Nm 2620 Nm 3280 Nm 3870 Nm
1 1/2 3060 Nm 2720 Nm 3455 Nm 4320 Nm 5100 Nm
Tightening torques, ORFS-

page
–
couplings
Pipe and hose coupling
Pipe diameter Tightening torques
mm inch Nm
6 1/4 23-25
8 5/16
33-38
10 3/8
12 1/2 51-57
14 -
15 - 80-90
16 5/8
18 3/4
120-130
20 -
22 7/8
150-170
25 1"

Pipe diameter Tightening torques
mm inch Nm
28 -
30 - 180-200
32 1"1/4
35 -
200-240
38 1"1/2
Socket width Tightening torques
mm inch Nm
17 11/16 23-25
22 13/16 33-38
24 15/16 51-57
36 1 3/8 120-130
41 1 5/8 150-170
Flange coupling
UNF-UN Metric-ISO BSSP

Thread Tightening torques Thread Tightening torques Thread Tightening torques (Nm)
(inch) (Nm) (mm) (Nm) (inch)
7/16-20 21 10x1 20 1/8-28 20
1/2-20 27 12x1,5 35 1/4-19 35
9/16-18 40 14x1,5 45 3/8-19 70
3/4-16 78 16x1.5 55 1/2-14 100
7/8-14 110 18x1.5 68 3/4-14 190
1"1/16-12 180 20x1.5 80 1"-11 300
1"3/16-12 230 22x1.5 98 1"1/4-11 330
1"5/16-12 285 26x1.5 170 1"1/2-11 400
1"5/8-12 320 27x2 180
1"7/8-12 400 33x2 310
42x2 330
48x2 400

Tightening torque, climate control

page
–
system connections
O-rings, radiator hoses
Hose diameter Thread Tightening torques
mm inch inch Nm
6 1/4" 7/16" 7-14 Nm
10 3/8" 5/8" 14-20 Nm
10 3/8" 11/16" 14-20 Nm
12 1/2" 3/4" 14-27 Nm
16 5/8" 7/8" 27-41 Nm
19 3/4" 1 1/16" 34-47 Nm
Pressure switch 3/8" 7-14 Nm
The above values are to be considered guidelines and may vary de-
pending on installation.
Unit explanations
page
–
Unit Abbreviation
Newton metre Nm
Kilo pound metre kpm
Kilo pascal kPa
Mega pascal MPa
Kilowatt kW
Kilojoule kJ
British termel unit Btu
Calorie ca
Inch in
Feet ft
Yard yd
Mile mile
Centimetre cm
Metre m
Kilometre km

Conversion table, SI-units

page
–
SI-unit Recalculation fac- Non-SI Recalculation fac- SI

tor tor
Torque
Nm x 10,2 = kg·cm x 0,8664 = lb·in
Nm x 0,74 = lbf·ft x 1,36 = Nm
Nm x 0,102 = kg·m x 7,22 = lb·ft
Pressure (Pa = N/m2)
kPa x 4,0 = in.H2O x 0,249 = kPa
kPa x 0,30 = in.Hg x 3,38 = kPa
kPa x 0,145 = psi x 6,89 = kPa
bar x 14,5 = psi x 0,069 = bar
kp/ cm2 x 14,22 = psi x 0,070 = kp/cm2
N/ mm2 x 145,04 = psi x 0,069 = bar
MPa x 145 = psi x 0,00689 = MPa
Power (W = J/s)
kW x 1,36 = hp (cv) x 0,736 = kW
kW x 1,34 = bhp x 0,746 = kW
kW x 0,948 = Btu/s x 1,055 = kW
W x 0,74 = ft·lb/s x 1,36 =W
Energy (J = Nm)
kJ x 0,948 = Btu x 1,055 = kJ
J x 0,239 = calorie x 4,19 =J
Speed and acceleration
m/s2 x 3,28 = ft/s2 x 0,305 = m/s2
m/s x 3,28 = ft/s x 0,305 = m/s
km/h x 0,62 = mph x 1,61 = km/h
Horsepower/torque
Bhp x 5252 rpm= TQ (lb·ft) TQ x rpm 5252 = bhp
Temperature
ºC = (ºF – 32)/1,8 ºF = (ºC x 1,8) + 32
Flow factor
l/ min (dm3 /min) x 0,264 = US gal/ min x 3.785 = litre/min

Conversion table, length

page
–
Unit cm m km in ft yd mile
cm 1 0,01 0,00001 0,3937 0,03281 0,01094 0,000006
m 100 1 0,001 39,37 3,2808 1,0936 0,00062
km 100000 1000 1 39370,7 3280,8 1093,6 0,62137
in 2,54 0,0254 0,000025 1 0,08333 0,02777 0,000015
ft 30,48 0,3048 0,000304 12 1 0,3333 0,000189
yd 91,44 0,9144 0,000914 36 3 1 0,000568
mile 160930 1609,3 1,6093 63360 5280 1760 1
1 mm = 0,1 cm - 1 mm = 0,001 m
Conversion table, area

page
–
Unit cm2 m2 km2 a ft2 yd2 in2
cm2 1 0,0001 - 0,000001 0,001076 0,000012 0,155000
m2 10000 1 0,000001 0,01 10,764 1,1958 1550,000
km2 - 1000000 1 10000 1076400 1195800 -
a 0,01 100 0,0001 1 1076,4 119,58 -
ft2 - 0,092903 - 0,000929 1 0,1111 144,000
yd2 - 0,83613 - 0,008361 9 1 1296,00
in2 6,4516 0,000645 - - 0,006943 0,000771 1
1ha = 100a - 1mile2 = 259ha = 2,59 km2
Conversion table, volume

page
–
Unit cm3 = cc m3 l in3 ft3 yd3
cm3 = ml 1 0,000001 0,001 0,061024 0,000035 0,000001
m3 1000000 1 1000 61024 35,315 1,30796
dm3 (l) 1000 0,001 1 61,024 0,035315 0,001308
in3 16,387 0,000016 0,01638 1 0,000578 0,000021
ft3 28316,8 0,028317 28,317 1728 1 0,03704
yd3 764529,8 0,76453 764,53 46656 27 1
1gal (US) = 3785,41 cm3 = 231in3 = 0,83267gal (UK)

Conversion table, weight

page
–
Unit g kg t oz lb
g 1 0,001 0,000001 0,03527 0,0022
kg 1000 1 0,001 35,273 2,20459
t 1000000 1000 1 35273 2204,59
oz 28,3495 0,02835 0,000028 1 0,0625
lb 453,592 0,45359 0,000454 16 1
1ton (metric) = 1.1023 ton (US) = 0.9842 ton (UK)
Conversion table, pressure

page
–
Unit kp/cm2 bar Pa = N/m2 kPa lbf/in2 lbf/ft2
kp/ cm2 1 0,98067 98066,5 98,0665 14,2233 2048,16
bar 1,01972 1 100000 100 14,5037 2088,6
Pa = N/m2 0,00001 0,001 1 0,001 0,00015 0,02086
kPa 0,01020 0,01 1000 1 0,14504 20,886
lbf/in2 0,07032 0,0689 6894,76 6,89476 1 144
lbf/ft2 0,00047 0,00047 47,88028 0,04788 0,00694 1
kg/cm2 = 735,56Torr (mmHg) = 0,96784atm


G Terminology and index 1
G Terminology and index
Table of Contents G Terminology and index

mm mm mm mm mm mm
Terminology and index.................................................................................. 3

Explanations ........................................................................................................... 3
Index ....................................................................................................................... 6

2 G Terminology and index

G Terminology and index – Terminology and index 3
Terminology and index

mm mm mm mm mm mm
Explanations
page
–
Term Description
Accumulator Reservoir that stores (accumulates) pressure for i.e. hydraulic functions.
Anti-corrosion compound Prevents oxidation, in simple terms, rustproofing.
Attachment The part of the machine that grips the load when lifting.
Axle distance Distance between drive axle and steering axle.
Bar Unit for measuring pressure.
Battery disconnect switch Cuts off current from battery.
Buzzer Acoustic alarm to catch the operator’s attention.
Control valve Valves that can be used to control something, e.g. release pressure and thus lower a
boom or a fork. See also control valve.
Daily inspection The actions that should be performed daily to ensure the machine’s functionality.
Decitonne Tenth of a tonne; measure of the machine’s lift capacity.
Display "Window" showing digital information on steering wheel panel in cab.
Drive axle Driving axle that receives the torque from the drivetrain.
Drive line Parts in machine involved in power transmission; engine, torque converter, transmission,
propeller shaft and drive axle with differential and hub reduction.
Dust reservoir The air filter collects the coarsest particles in a dust reservoir, which empties automatically
while driving.
ECC Electric Climate Control. Climate control system with thermostat-controlled cooling, dehu-
midification and heating.
EHC Electric Heat Control. Heater system with thermostat heating control.
Electrolyte level Fluid level in battery cells.
End position As far out or away as the object can be moved, e.g. end position for tilt cylinders.
Environmental waste Used oils, filters, etc., must be handled according to governing national laws and regula-
tions.
Expansion tank Coolant reservoir, with space for the fluid to change volume due to temperature differenc-
es.
Fixed displacement Pump with fixed pump volume.
Fork mounting Mounting for forks, mounted on the lifting carriage.
Forks Lifting device that lifts the loads.
Frame member Structural members in the frame.
Hanging load Raised load.
Hub reduction Type of final drive (often next to drive wheel) that reduces rpm and increases torque from
the drivetrain.
Hydraulic oil Oil for hydraulic system. See specifications in operator’s manual.
Hydraulic oil pump Pump in the hydraulic system.
Hydraulic system System that uses oil pressure to transfer power to different functions.

4 G Terminology and index – Terminology and index
Term Description
Indicator Mechanical "sensor", for example, shows that a filter is clogged and needs to be changed.
Inverted forks Upside-down forks, for lifting and mounting of top lift.
LC Load centre
Levelling The forks/attachment are/is tilted, for example, if load stands on uneven ground.
Lifting capacity Indicates machine’s maximal lift capacity.
Lifting carriage Lifts the load, located on the mast.
Lifting point Attaching point for lifting device when lifting an object.
Low emission engine Engine with low emissions of hazardous substances. Manufactured in accordance with
regulations.
Machine model Machine type. Indicated as, for example: DCF370-500. See also type designation.
Main fuse Located by battery. Cuts off current to all systems in machine.
Maintenance Periodic maintenance operations so that the machine functions safely and lasts well.
Mast Carrier of lifting carriage, forks, attachment and load.
Operating time Number of hours machine has been in operation, shown on hour meter in cab.
Option Optional equipment for machine.
Pilot oil pressure A low control pressure to, for example, a valve.
Planetary gear Type of gearbox with the gears in constant mesh.
Product alternative One of several alternatives selected for a machine, i.e. engine alternative.
Progressive steering Quick steering wheel movements give greater steering angle.
Proportional valve An electromagnetically controlled valve. If a current is applied, the valve is activated in
proportion to the current’s amplitude. In simple terms, infinitely variable valve, as opposed
to on/off valve. For example, on the transmission valve housing.
Recirculation Circulate over and over again.
Refrigerant Fluid/gas in the climate control system. Must only be handled by authorised trained per-
sonnel.
Securing machine for transport Actions before transporting machine.
Serial number Unique machine designation. On the machine plate.
Service position How machine should be safely positioned before service may be started.
Servo Power amplifier. A small movement by the user generates great displacement, e.g. power
steering.
Servo pressure A low control pressure to control a higher pressure, for example to a valve.
Side shift The forks/attachment are/is moved parallel sideways.
Solenoid valve An electro magnetically controlled valve. See also proportional valve.
Spirit Delta Enclosed type of cab.
Spreading Spreading of the forks (i.e. change the distance between them) / Widening of attachment.
Start-up Start-up procedure for the control system (from de-enerised to energised).
Steering axle Wheel axle with steering.
Tilting The mast is tilted forwards or backwards.
Top lift Attachment. See attachment.

Term Description
Torque converter Hydraulic, stepless clutch.
Transmission oil Oil for gearbox and torque converter. See specifications in operator’s manual.
Twistlocks Four lock pins - one in each corner of the attachment - pushed down in corresponding
holes in the container and twisted to lock the container when lifting.
Type designation Indicates machine type and capacity. See also machine model.
Valve spool Movable part in valve. Determines oil’s path.
Variable displacement. Regulatable volume (capacity) in a pump.
Variable pump Pump with adjustable flow rate.
Wet brakes Brake friction plates in an oil bath.
Working hydraulics All load handling functions, i.e. lift and lower, tilt, side shift, spreading and levelling.

Index
page
–
Designation Section Function group

A near accident is a warning! B Safety -
About the documentation A Foreword -
About the machine version A Foreword -
About the Workshop Manual A Foreword -
Accelerator pedal 1 Engine 1.1.2
Accumulator 4 Brakes 4.3.4
Accumulator charging valve 4 Brakes 4.3.3
Accumulator charging valve 4 Brakes 4.8.4
Accumulator charging valve 10 Common hydraulics 10.5.4
Accumulator drain valve 10 Common hydraulics 10.2.1
Accumulator servo circuit 7 Load handling 7.2.2
Air cleaning system 1 Engine 1.6.1
Air distributor 9 Frame, body, cab and accessories 9.4.14
Air intake and exhaust outlet 1 Engine 1.6
Air pollution B Safety -
Air suspension 9 Frame, body, cab and accessories 9.3.5
Air vents 9 Frame, body, cab and accessories 9.4.15
Alternator 11 Common electrics 11.4
Alternator 11 Common electrics 11.4.1
Armrest 9 Frame, body, cab and accessories 9.3.11
ATTACH, DCF 90-100 with lifting hook attachment 8 Control system 8.4.9
ATTACH, DCF 90-100 with twistlock attachment 8 Control system 8.4.9
ATTACH, DCF360-450CSG 8 Control system 8.4.9
Auxiliaries 10 Common hydraulics 10.7
Back cushion 9 Frame, body, cab and accessories 9.3.2
Batteries 11 Common electrics 11.3
Battery disconnect switch 11 Common electrics 11.2.1
Body 9 Frame, body, cab and accessories 9.13
Brake fluid filter 4 Brakes 4.3.2


Brake fluid pump 4 Brakes 4.5.1
Brake fluid tank 4 Brakes 4.8.1
Brake light 9 Frame, body, cab and accessories 9.6.4
Brake pedal 4 Brakes 4.1.1
Brake system fluid 4 Brakes 4.8.14
Brake valve 4 Brakes 4.3.5
Breather filter hydraulic oil tank 10 Common hydraulics 10.6.6
Breather filter, brake fluid tank 4 Brakes 4.8.11
Bypass 8 Control system 8.2.2
CAB 8 Control system 8.4.3
Cab fan 9 Frame, body, cab and accessories 9.4.3
Cab frame 9 Frame, body, cab and accessories 9.10.1
Cab interior 9 Frame, body, cab and accessories 9.11
Cab structure and suspension 9 Frame, body, cab and accessories 9.10
Cab tipping 9 Frame, body, cab and accessories 9.10.5
Cab undercarriage 9 Frame, body, cab and accessories 9.10.3
Cables 11 Common electrics 11.5.5
Calibration 8 Control system 8.5.2
CAN bus drivetrain 11 Common electrics 11.6.3
CAN/POWER 8 Control system 8.4.1
CAN-bus 11 Common electrics 11.6.1
Carpet boom 7 Load handling 7.9.2
Central lubrication 9 Frame, body, cab and accessories 9.14
Circuit diagram, description E Schematics -
Circuit diagrams, compilation E Schematics -
CLIMATE 8 Control system 8.4.4
Clothing, etc. B Safety -
Communication 11 Common electrics 11.6
Communication between PC and machine 11 Common electrics 11.6.4
Complete machine, description 0 Complete machine -
Component designations E Schematics -
Compressed air-suspended seat 9 Frame, body, cab and accessories 9.3.6


Compressor 9 Frame, body, cab and accessories 9.4.7
Condenser 9 Frame, body, cab and accessories 9.4.8
Conditions A Foreword -
Control lever 7 Load handling 7.1.1
Control system D Error codes -
Control system engine 1 Engine 1.9
Control unit transmission 2 Transmission 2.8.1
Control unit, engine 1 Engine 1.9.1
Control units 11 Common electrics 11.5.3
Control valve load handling 7 Load handling 7.2.6
Control valve, mini-wheel/lever steering 5 Steering 5.2.10
Controls and instruments 1 Engine 1.1
Controls and instruments 2 Transmission 2.1
Controls and instruments 4 Brakes 4.1
Controls and instruments 5 Steering 5.1
Controls and instruments 7 Load handling 7.1
Controls and instruments 8 Control system 8.1
Controls and instruments 9 Frame, body, cab and accessories 9.1
Conversion table, area F Technical data -
Conversion table, length F Technical data -
Conversion table, pressure F Technical data -
Conversion table, SI-units F Technical data -
Conversion table, weight F Technical data -
Conversion table, volume F Technical data -
Coolant 1 Engine 1.7.7
Coolant B Safety -
Cooler hydraulic oil 10 Common hydraulics 10.6.2
Cooling fan 1 Engine 1.7.5
Cooling fan 4 Brakes 4.8.9
Cooling fan 10 Common hydraulics 10.6.3
Cooling system 1 Engine 1.7


Cooling system 2 Transmission 2.7
Copyright A Foreword -
Counterweights 9 Frame, body, cab and accessories 9.13.4
Diagnostics 8 Control system 8.4
Directional valve, reversible operator’s seat 5 Steering 5.2.15
Directional valve, reversible operator’s seat 9 Frame, body, cab and accessories 9.3.12
Distribution block 9 Frame, body, cab and accessories 9.14.2
Distribution of electricity 11 Common electrics 11.5
Documentation sections A Foreword -
Doors 9 Frame, body, cab and accessories 9.10.2
Drive axle 3 Driveline/axle 3.3
Drive axle block 4 Brakes 4.3.6
Drive axle block 4 Brakes 4.8.5
Driving direction indicator 9 Frame, body, cab and accessories 9.6.6
Electric heater 9 Frame, body, cab and accessories 9.3.3
Electric motors B Safety -
Electric protection 11 Common electrics 11.2
Electrical distribution box 11 Common electrics 11.5.2
ELSERV 8 Control system 8.4.8
Emergency stop switch 9 Frame, body, cab and accessories 9.2.1
Emergency stop switch 11 Common electrics 11.2.3
Engine D Error codes -
ENGINE 8 Control system 8.4.6
Engine heater 1 Engine 1.7.10
Engine temperature sensor 9 Frame, body, cab and accessories 9.4.6
Entertainment and communication 9 Frame, body, cab and accessories 9.8
Environment B Safety -
Error code menu 8 Control system 8.1.10
Error code menu, description D Error codes -
Error codes (Cummins QSM 11 engine) D Error codes -
Error codes (Volvo TAD1250VE engine) D Error codes -
Error codes (Volvo TAD950VE and TAD952VE engines) D Error codes -
Error codes engine (engine alternative Volvo TAD760VE) D Error codes -
Error codes engine, general D Error codes -


Error codes machine D Error codes -
Error codes, explanation D Error codes -
Error codes, transmission D Error codes -
Exhaust system 1 Engine 1.6.3
Expansion valve 9 Frame, body, cab and accessories 9.4.11
EXTRA 8 Control system 8.4.11
Feedback A Foreword -
Felkoder motor (motoralternativ Cummins QSB6.7) D Error codes -
Fenders 9 Frame, body, cab and accessories 9.13.1
Fire and explosion risks B Safety -
Fire extinguisher 9 Frame, body, cab and accessories 9.2.3
Flashing hazard lights 9 Frame, body, cab and accessories 9.6.7
Flashing hazard lights 9 Frame, body, cab and accessories 9.7.2
Flex plates 2 Transmission 2.2.1
Floor covering 9 Frame, body, cab and accessories 9.11.4
Fluid or gas under pressure B Safety -
Footstep and rail 9 Frame, body, cab and accessories 9.13.3
Fork mounting 7 Load handling 7.4.10
Form for copying A Foreword -
Frame 9 Frame, body, cab and accessories 9.12
Fresh air and recirculation damper 9 Frame, body, cab and accessories 9.4.2
Fresh air filter 9 Frame, body, cab and accessories 9.4.1
Fuel system 1 Engine 1.2
Fuel system B Safety -
Fuel tank 1 Engine 1.2.1
Function descriptions A Foreword -
Function group structure A Foreword -
Fuses 11 Common electrics 11.2.2
Gear selector and multi-function lever 2 Transmission 2.1.1
Gear selector and multi-function lever 9 Frame, body, cab and accessories 9.1.1
General A Foreword -
General B Safety -
General B Safety -
General safety information B Safety -


Glass/windows/mirrors 9 Frame, body, cab and accessories 9.9
Headlights 9 Frame, body, cab and accessories 9.6.1
Heat exchanger cooling 9 Frame, body, cab and accessories 9.4.13
Heat exchanger heat 9 Frame, body, cab and accessories 9.4.4
Heating, ventilation and air conditioning 9 Frame, body, cab and accessories 9.4
Hood engine compartment 9 Frame, body, cab and accessories 9.13.2
Horn 9 Frame, body, cab and accessories 9.7.1
Hoses, pipes and valves 10 Common hydraulics 10.5
HYD 8 Control system 8.4.5
Hydraulic and brake systems, depressurizing B Safety -
Hydraulic cylinders 10 Common hydraulics 10.7.1
Hydraulic diagram, basic machine DCF 280-330, electric E Schematics -

servo and freelift
Hydraulic diagram, basic machine DCF 280-330, hydrau- E Schematics -

lic servo

lic servo, brake fluid tank

lic servo, log grapple
Hydraulic diagram, basic machine DCF370-500, electric E Schematics -

servo
Hydraulic diagram, basic machine DCF370-500, electric E Schematics -

servo, brake fluid tank
Hydraulic diagram, basic machine DCF370-500, hydrau- E Schematics -

lic servo
Hydraulic diagram, separate top lift attachment E Schematics -
Hydraulic diagrams, compilation E Schematics -
Hydraulic oil 10 Common hydraulics 10.6.8
Hydraulic oil fine-filter 10 Common hydraulics 10.6.9
Hydraulic oil pump 4 Brakes 4.3.1
Hydraulic oil pump 4 Brakes 4.8.3
Hydraulic oil pump 5 Steering 5.2.1
Hydraulic oil pump 7 Load handling 7.2.1


Hydraulic sliding cab 9 Frame, body, cab and accessories 9.10.4
Ignition switch 1 Engine 1.1.1
Important information A Foreword -
Initiation 8 Control system 8.5.1
Instrument and control panels 9 Frame, body, cab and accessories 9.11.1
Insulation 9 Frame, body, cab and accessories 9.11.5
Intercooler 1 Engine 1.6.4
Interior details, plastic 9 Frame, body, cab and accessories 9.11.2
Interior details, textile 9 Frame, body, cab and accessories 9.11.3
Interior lighting 9 Frame, body, cab and accessories 9.6.11
Joystick 5 Steering 5.1.3
Lift cylinder 7 Load handling 7.2.7
Lift forks 7 Load handling 7.9.1
Lifting carriage 7 Load handling 7.2.11
Lifting equipment B Safety -
Lifting heavy components B Safety -
Lifting/lowering 7 Load handling 7.2
Lighting system 9 Frame, body, cab and accessories 9.6
LIGHTS 8 Control system 8.4.2
Lines 9 Frame, body, cab and accessories 9.14.3
Link arm 5 Steering 5.2.6
Load carrier 7 Load handling 7.9
Load control valve 7 Load handling 7.2.13
Load retention valve 7 Load handling 7.7.6
Lubrication 2 Transmission 2.6
Machine card A Foreword -
Mast 7 Load handling 7.2.9
Mast 7 Load handling 7.7.9
Mast position sensor 7 Load handling 7.2.10
Mechanical seat adjustment 9 Frame, body, cab and accessories 9.3.7
Mini-wheel 5 Steering 5.1.2
Moisture filter 9 Frame, body, cab and accessories 9.4.9


Monitor, reversing camera 9 Frame, body, cab and accessories 9.9.7
Monitoring 8 Control system 8.2
M-valve parking brake 4 Brakes 4.5.3
NC (normally closed) switch, brake pressure 4 Brakes 4.3.7
NO (normally open) switch, brake lights 4 Brakes 4.3.8
NO (normally open) switch, coolant level 1 Engine 1.7.8
Noise B Safety -
Normally closed (NC) switch, disengagement 2 Transmission 2.8.2
Nut, washer and clamp 6 Suspension 6.3.3
Oil cooler 2 Transmission 2.6.3
Oil cooler 2 Transmission 2.7.3
Oil cooler 4 Brakes 4.8.7
Oil filter 10 Common hydraulics 10.6.7
Oils B Safety -
Oils and lubricants, recommendation F Technical data -
OLS 8 Control system 8.4.10
Ordering of documentation A Foreword -
Other functions 7 Load handling 7.10
Overload protection 8 Control system 8.2.1
Paint/coatings 9 Frame, body, cab and accessories 9.15
Parking brake NC switch 4 Brakes 4.5.5
Parking brake system 4 Brakes 4.5
Parking brake unit 4 Brakes 4.5.4
Passenger seat 9 Frame, body, cab and accessories 9.3.8
Pause heater 9 Frame, body, cab and accessories 9.4.19
Pipes and hoses 4 Brakes 4.3.10
Pipes and hoses 5 Steering 5.2.14
Pipes and hoses 7 Load handling 7.2.12
Pipes and hoses 10 Common hydraulics 10.2.3


Power assisted system 5 Steering 5.2
Power supply 11 Common electrics 11.5.1
Power-assisted brake system 4 Brakes 4.3
Pressure reducer 7 Load handling 7.2.3
Pressure switch 9 Frame, body, cab and accessories 9.4.10
Priority valve 5 Steering 5.2.2
Priority valve 10 Common hydraulics 10.5.2
Product alternatives and optional equipment A Foreword -
Propeller shaft 3 Driveline/axle 3.2
Proportional valves 10 Common hydraulics 10.5.5
Pump unit 9 Frame, body, cab and accessories 9.14.1
Pumps 10 Common hydraulics 10.4
Radiator and expansion tank 1 Engine 1.7.4
Radiator bypass valve 10 Common hydraulics 10.6.5
Read the Maintenance Manual A Foreword -
Read the Operator’s Manual A Foreword -
Reading instructions A Foreword -
Reading out error code D Error codes -
Reading-lamp 9 Frame, body, cab and accessories 9.11.8
Rear window 9 Frame, body, cab and accessories 9.9.4
Rearview mirror 9 Frame, body, cab and accessories 9.9.5
Redundant CAN bus 11 Common electrics 11.6.2
References between different information types A Foreword -
Refrigerant B Safety -
Reversible operator’s seat sensor 9 Frame, body, cab and accessories 9.3.13
Reversible operator's seat 9 Frame, body, cab and accessories 9.3.9
Reversing alarm 9 Frame, body, cab and accessories 9.7.5


Reversing camera 9 Frame, body, cab and accessories 9.9.6
Reversing light 9 Frame, body, cab and accessories 9.6.5
Rims 6 Suspension 6.3.2
RMI (Remote Machine Interface) 11 Common electrics 11.6.5
Roof grating 9 Frame, body, cab and accessories 9.2.5
Roof window 9 Frame, body, cab and accessories 9.9.3
Rotating beacon 9 Frame, body, cab and accessories 9.6.8
Rotating beacon 9 Frame, body, cab and accessories 9.7.3
Rotating components and tools B Safety -
Rotating operator’s seat 9 Frame, body, cab and accessories 9.3.10
Running light 9 Frame, body, cab and accessories 9.6.2
Safety and emergency equipment 9 Frame, body, cab and accessories 9.2
Safety concerns everyone! B Safety -
Safety instructions B Safety -
Safety valves 10 Common hydraulics 10.2
Seat 9 Frame, body, cab and accessories 9.3
Seat belt 9 Frame, body, cab and accessories 9.2.2
Seat buzzer 9 Frame, body, cab and accessories 9.2.4
Seat cushion 9 Frame, body, cab and accessories 9.3.1
Sensor brake oil temperature 4 Brakes 4.8.10
Sensor cab temperature 9 Frame, body, cab and accessories 9.4.17
Sensor hydraulic oil temperature 10 Common hydraulics 10.6.4
Sensor operator in seat 9 Frame, body, cab and accessories 9.3.14
Sensor outdoor temperature 9 Frame, body, cab and accessories 9.4.18
Sensor temperature outlet fan 9 Frame, body, cab and accessories 9.4.16
Sensor temperature refrigerant 9 Frame, body, cab and accessories 9.4.12
Sensor, fuel level 1 Engine 1.2.2
Sensor, reversible operator’s seat 5 Steering 5.2.16
Separate top lift attachment 7 Load handling 7.10.5
Service indicator 8 Control system 8.2.4
Service position B Safety -
Servo filter 7 Load handling 7.2.4


Settings 8 Control system 8.5
Several mechanics on the same machine B Safety -
Shock absorbers 9 Frame, body, cab and accessories 9.3.4
Shuttle valve 5 Steering 5.2.9
Shuttle valve 10 Common hydraulics 10.5.3
Shuttle valve, dual brake pedals 4 Brakes 4.3.11
Shuttle valve, mini-wheel/lever steering 5 Steering 5.2.11
Side shift 7 Load handling 7.4
Side shift cylinder 7 Load handling 7.4.6
Side shift cylinder 7 Load handling 7.5.6
Side window 9 Frame, body, cab and accessories 9.9.2
Signalling system 9 Frame, body, cab and accessories 9.7
Solvents B Safety -
Specification for lifting capacity and dimensions F Technical data -
Specifications for data and volume F Technical data -
Speed limitation 8 Control system 8.2.3
Spreading 7 Load handling 7.5
Start battery 11 Common electrics 11.3.1
Start/stop 1 Engine 1.11
Starter motor 1 Engine 1.11.1
Steering angle sensor 5 Steering 5.2.12
Steering axle cradle 5 Steering 5.2.5
Steering axle cradle 6 Suspension 6.2.1
Steering cylinder 5 Steering 5.2.4
Steering valve 5 Steering 5.2.3
Stopping device 1 Engine 1.11.2
Storage A Foreword -
Sun blinds 9 Frame, body, cab and accessories 9.11.6
Suspension 6 Suspension 6.2
Switch, direction indicators 9 Frame, body, cab and accessories 9.1.22
Tail light 9 Frame, body, cab and accessories 9.6.3
Tank 10 Common hydraulics 10.3.1
Tank heater 4 Brakes 4.8.2


Tank heater 10 Common hydraulics 10.6.1
Tanks and accumulators 10 Common hydraulics 10.3
Temperature control, brake fluid cleaning 4 Brakes 4.8
Temperature control, cleaning and hydraulic oil 10 Common hydraulics 10.6
Tensioned springs B Safety -
Terminal console 9 Frame, body, cab and accessories 9.11.7
Thermal bypass valve 4 Brakes 4.8.8
Tightening torque, climate control system connections F Technical data -
Tightening torques, ORFS-couplings F Technical data -
Tightening torques, recommendations F Technical data -
Tilt 7 Load handling 7.7
Tilt cylinder 7 Load handling 7.7.7
Torque converter/Clutch system 2 Transmission 2.2
TRANSM 8 Control system 8.4.7
Transmission D Error codes -
Transmission cable harness 2 Transmission 2.8.3
Transmission control system 2 Transmission 2.8
Troubleshooting cable harness 0 Complete machine -
Troubleshooting hydraulic hoses 0 Complete machine -
Troubleshooting with error code, example 0 Complete machine -
Troubleshooting without an error code, example 0 Complete machine -
Troubleshooting, general work instructions 0 Complete machine -
Tyres 6 Suspension 6.3.1
Tyres and rims 6 Suspension 6.3
Tyres and rims B Safety -
Unit explanations F Technical data -
Vane pump with fixed displacement 10 Common hydraulics 10.4.3
Warning information A Foreword -
Warning parking brake 9 Frame, body, cab and accessories 9.7.4
Washer motor and reservoir 9 Frame, body, cab and accessories 9.5.4
Water valve 9 Frame, body, cab and accessories 9.4.5
Wheel brake 4 Brakes 4.3.9
Wheel brake 4 Brakes 4.8.6
Wheel hub 5 Steering 5.2.8


Wheel hub 6 Suspension 6.2.3
Wheel spindle 5 Steering 5.2.7
Wheel spindle 6 Suspension 6.2.2
Vibrations B Safety -
Windscreen 9 Frame, body, cab and accessories 9.9.1
Wiper front 9 Frame, body, cab and accessories 9.5.1
Wiper motor, front 9 Frame, body, cab and accessories 9.5.5
Wiper motor, rear 9 Frame, body, cab and accessories 9.5.7
Wiper motor, roof 9 Frame, body, cab and accessories 9.5.6
Wiper rear 9 Frame, body, cab and accessories 9.5.3
Wiper roof 9 Frame, body, cab and accessories 9.5.2
Wiper/washer system 9 Frame, body, cab and accessories 9.5
Working lights, cab 9 Frame, body, cab and accessories 9.6.10
Working lights, mast 9 Frame, body, cab and accessories 9.6.9
Working under machine B Safety -
Workshop manual contents A Foreword -
Writing desk 9 Frame, body, cab and accessories 9.11.9

DCF 280-500 Workshop Manual PDF

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A Foreword

9 Frame, body, cab and accessories

G Terminology and Index

Table of Contents A Foreword

Workshop manual DCF 280-500 VDCF02.02GB

VDCF02.02GB Workshop manual DCF 280-500

About the Workshop Manual

Thank you for choosing Kalmar Industries as your machine supplier.

The instructions are based on the use of generally available standard

About the machine version

The information in this publication corresponds to the machine's de-

Workshop manual DCF 280-500 VDCF02.02GB

Warnings inform on potential dangers which can, if the warnings are

Important information marked with NOTE facilitates the work process,

Read the Operator’s Manual

The symbol to the left is sometimes found on the machine. It refers to

Read the Operator’s Manual

Read the Maintenance Manual

The symbol to the left is sometimes found on the machine. It refers to

Read the Maintenance Manual

VDCF02.02GB Workshop manual DCF 280-500

Workshop manual contents

The Workshop Manual contains information to facilitate maintenance

A Foreword General information about the workshop manual's purpose, con-

B Safety Keep in mind for your safety.

C Preventive maintenance Reference to maintenance manual: Preventive maintenance.

E Schematics Wiring diagrams, hydraulic diagrams and list of electrical compo-

F Technical data Technical data, conversion tables, information for conversion of

Workshop manual DCF 280-500 VDCF02.02GB

Function group structure

The information in the manual is divided into a structure of functions at

VDCF02.02GB Workshop manual DCF 280-500

References between different information types

The maintenance manual and workshop manual are mainly divided

Function descriptions Hydraulic diagrams

Component descriptions Error codes

Diagnostics Wiring diagrams

• From Function description to Component description, to enable

Workshop manual DCF 280-500 VDCF02.02GB

Product alternatives and optional equipment

The information in the manual is divided into modules. If a product al-

Optional equipment refers to options that can be added to standard

VDCF02.02GB Workshop manual DCF 280-500

Function descriptions are schematic overviews that describe how a

10 7 Lasthantering 7.2 Lyft och s nk

Lyft och s nk, funktionsbeskrivning (elservo)

F ruts ttning B rv rde H nvisning

Pos F rklaring Signalbeskrivning H nvisning

2 Tryckreduceraren minskar tryck fr n hy- P = 3,5 MPa Tryckreducerare, beskrivning sida 17

4 Servofiltret renar oljan innan man ver- - Servofilter, beskrivning sida 19

VDCF02.02SE Verkstadsmanual DCF 280-330, DCF 370-500

Workshop manual DCF 280-500 VDCF02.02GB

1. Flag diagnostics, indicates that the signal can be checked with a

VDCF02.02GB Workshop manual DCF 280-500

Symbol explanation function descriptions

D790-1 13. Bulb

13 14 14. Control system, two control units with CAN-bus

Workshop manual DCF 280-500 VDCF02.02GB

About the documentation

The documentation to the machine comprises the following sections:

Documentation is available for order from Kalmar Industries dealers.

VDCF02.02GB Workshop manual DCF 280-500

Kalmar Industries’ ambition is that you who work with maintenance of